Your Input, Transfer case FUBAR?

[DELTAJOHN]

My truck is a 2004 F-250 torqshift auto 6.0 diesel.
Here's my problem, about a week ago went to shift into 4X4 high in a snow storm. I was doing about 35 mph. Now this is my 4th ESOF vehicle, 1 Expedition, 2 F-150's prior. I first backed off the throttle, THEN flipped the lever. I got this nasty grind noise, so I flipped the switch back to 2WD. I tried it again after 10 minutes at a slower speed, same deal. Tried it sitting still, it would shift into 4WD high and 4WD low.

Tried it later yet, it won't shift at all. I found fuse 111, the 30A 4X4 ESOF fuse blown. I replaced it, it blew again when I tried to shift it in 4X4. I replaced the shift motor, the same deal, blown fuse. I noticed that when I turned the shift cog on the transfer case to put it in 4X4 to line up the motor, it took a lot of effort to turn that cog, the book says 35 ftlbs of effort is generated by the shift motor to turn that cog, if the shift effort is more will it blow the fuse? I was under the impression that the 4X4 module would "retry" a shift if it couldn't make it instead of blowing the fuse.

I'm wondering if I have a bent shift rod, or fork, or messed up synchronizer clutch in the transfer case? I have rebuilt old NP 208F transfer cases back in the '80's but I don't recall shift effort this hard. What do Y'all think, anyone else run into this?

John

[jeeplj8]

I guess the first question should be, when was the last time you changed the t-case fluid?

As for trying to diagnose your problem, are you able to engage 4wd with the electric shift motor removed? If so, engage it, get in a drive a little bit. Everything work OK?