hey guys i have a 93 f150 5.0 4x4 with the aod and the borg warner transfer case. i also have manual warn hubs.
i was on here the other day asking abotu some squeaking i thought was my trans. i was told to change the fluid in my transfer case as that was probably the issue. turned out it was damn near empty. less that one quart came out.
i put in 2.5 quarts and filled it. the haynes manual says 6.5qts. but as the fluid was draining from the fill plug, i put the plug back in. now it wont shift into 4low. i kept trying to cycle the transfer case.

when i shifted the tcase into 4hi i could NOT spin the front drive shaft by hand. but the light in the dash was not on and it didnt really feel like thw front wheels were pulling. i pulled the lever back to 4low while i was in neutral and it wouldnt engage at all. its like it was in neutral. i pulled back even farther and heard the gears grinding. i pulled even harder and it slammed into gear, the 4x4 light came on, then the light went out and it was like it was in neutral again.

i climbed under the truck and checked the linkage and everything seems ok. there is a little play in it, but it doesnt seem like alot.

i pulled the handle back as far as i could, put it in park and climbed under it again and the little nipple that sits in the u pieces was in between both "u's"
is there something i can do or adjust? or do i need to drop the tcase and go from there?

sorry this is small book. thanks for all the help guys!

 

Sounds like by time you checked your transfer case fluid level the damage was done.
Swapping in a junk yard T case will be the cheapest way to go.

 

so she's dead? lol weak! lol i just checked my local pull a part and its 120 bucks to get one. as far finding another one, will any 5.0 manual shift fit? as far as 80's to 96? or does it have to be the exact one i have?

 

When a T.case is low on fluid it starves the upper bearings until they over heat and ruins them.

Just get the same t case that came stock in your truck. 120 bucks is a good price.
To bad your not closer...I have 2 sitting in the back of my diesel!

 

now that i have fluid in her though, can i still drive it in 2wd without it being a safety issue?

edit: and once i get one in about a week or two, can i just split it open and spray it down with brake cleaner to clean the inside? i have plenty of left over fluid from today to fill it with clean fresh fluid.

 

No! Do not split the case! Just drain it and add new fluid.

 

If you're saying you're going to split the old case then go for it, but don't split the new case.

 

ok cool. thanks for the heads up and thanks so much for the help!!

 

ok. so when i got to work and put the truck in reverse, it just sounds like gears grinding. the same sound as before when i thought it was the transfer case. it goes forward fine, but no reverse. will a 1987 transmission and transfer case bolt up to my 1993 engine?

edit: its off an 87 bronco 5.0. and its an automatic.

 

What about your transfercase not shifting into low?