Line82

Hello,

I was wondering if there were any common problems regarding the transfer case. I have a 1993 F150 5.0L manual transmission 4-wheel drive. It is a manual-shift transfer case also.

I do not have 4-wheel drive Hi. I do have 4-wheel drive Lo range however. The 4x4 used to work perfectly. But one day, the 4x4 Hi was stuck on. I tried moving the transfer case shift lever around, and wound up breaking the linkage. The 4x4 Hi stuck on for the remainder of the ride. I unlocked the wheel hubs for the rest of the ride because I was driving on dry pavement. I didn't do anything to it, and the truck sat parked in the driveway overnight. In the morning, the 4x4 indicator was not illuminated anymore. I crawled underneath the truck and manually shifted the linkage into what I thought were the proper positions. I can only get it into 4x4 Lo. Any thoughts? Thank you

techrep

iTrader: (1)

you can remove the front drive shaft until you can solve your t-case problem

Mathew Reid

I've just revived a '92, and have discovered a similar issue. No hi gear (no 2x4 or 4x4), only low gear 4x4. I did discover that if I leaned forward on the transfer case shifter, it would engage, but felt as if I were right on the edge of teeth. Once it came time to shift to 2nd, I had to let go, and it would go to transfer case N. My shifter does move fluently as I think it should though.

My linkage looks good. I'll do some research tonight/tomorrow, and will probably end up tearing mine apart & ordering parts. Suspecting internal shift parts issues, or hi gear problem.

Line82

Hi, I wound up putting in a new linkage and everything works as it should. Cost me almost $100 but it works great.

Mathew Reid

R&I, disassembled my transfer case on Saturday. The low/hi shift fork is mangled. Should be an easy fix! Will be swapping in some new U-joints during re-assembly as well!

Mathew Reid

Done! Disassembled Saturday with nothing more complex than a torx bit & snap ring tools. Ordered hi/low shift fork, seal kit, & oil pump for $76-ish shipped, from www.zbag.com, monday morning. Had my new parts Tuesday afternoon! All cleaned up now, reassembled & functioning normally on the bench, will hopefully install Saturday.

Also planning 3 new U-joints, 2 ball joints, lockout hubs, rear main seal, oil pan gasket, & 4 new tires ... if theres time...