Transfer Case Control Lever Removal Procedure?? - Ford Powerstroke Diesel Forum
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Old 05-17-2011, 09:14 AM
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Transfer Case Control Lever Removal Procedure??

I am suffering from what seems to be a pretty common problem on these trucks, that is, the seizing up of the transfer case control lever.

I can get into 4H smooth as silk but I am unable to depress the control lever to get into the N and 4L positions. Seems to me the control lever mechanism is just seized up and probably corroded.

Can anyone point me to a removal procedure write up on this or provide some tips and guidance? Have tried Pblasting it from underneath and using a rubber mallet on shifter to try to free it up from above but no use. I can see the thing right there above the rear of the transmission but I am unsure of how to proceed with removal so I can overhaul this device or even replace it if necessary.

Thanks for reading.
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Old 05-18-2011, 06:36 PM
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You will want to take it apart and clean/re-lube it. The crucial operation is using something like a battery terminal puller to push the pin out of the retainer on the tie-bar from the lever to the transfer case. If you try to pry the bar off, it will likely break the pin off the casting, and you will need a new shifter, which is $400 from ford. After that, just remove the bolts that hold the plate/mechanism to the transmission housing.
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Old 05-21-2011, 03:51 PM
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Alternative - note: this is secondhand, based on a recent thread on another site - cut off the pin that interfaces with the lockout mechanism that requires you to push down the lever. In the olden days, the lever didn't have this lockout and you didn't need to push it down to get to Neutral or 4L. Cutting off the pin makes it work the way it used to. You still feel the detents of each position as they come from within the TC.
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Old 05-22-2011, 12:09 PM
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Thanks for your replies and good advice, gentlemen. Much appreaciated.
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