Problem Shifting Transfer Case to N or 4Low - Ford Powerstroke Diesel Forum
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post #1 of 9 Old 07-14-2010, 07:14 PM Thread Starter
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Question Problem Shifting Transfer Case to N or 4Low

I'm running a '96 F-250 with the 7.3 Liter Powerstroke Diesel. I have a manual transfer case shifter, one of the shifters that you have to push toward the floor to get from 4H to N or 4L. The problem is that the shifter will NOT move down at all to clear the low spot on the bracket that is necessary to get it into N or 4L. It can shift between 2H and 4H just fine. I recently bought the truck, so I believe that it may have seized up due to lack of use.

I already removed the boot from the floor. I see that there is a boot up towards where the shift handle bolts on, and one at the bottom. I figure it's spring loaded so as to require the downward push, and the springs are under those boots. Apparently, on mine, everything's rusted together under those boots. I can provide pictures, if that would help anybody solve my problem.

I want to take the piece that the shift handle bolts onto out, but I cannot seem to figure out how to remove the keepers on the linkages. If anybody could let me know how to take them off, that'd be great. They're round on the end, so I can't just unbolt them.

I realize that I'm new here, but please help me solve this problem. Like I said before, I can provide pictures of any of this, if necessary. Thank you in advance for any help. I can also provide more information about the vehicle or the problem, if necessary.
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post #2 of 9 Old 07-15-2010, 03:08 AM
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Photos would help

-John
Rudy's Diesel Performance - 919-383-9300 - Diesel Tech

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post #3 of 9 Old 07-15-2010, 07:54 AM
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Make sure your transmission is in park or Neutral before you try going to N or Lo if you have an auto.

1995 7.3L 4x4 Super Cab
236,000 Miles
4" MBRP Turbo Back
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post #4 of 9 Old 07-15-2010, 09:58 AM Thread Starter
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It's a manual transfer case, and I have narrowed the problem to the spring loaded cylinder. I just need to know how to disconnect that assembly from the linkages.

I'm going to get pictures now.
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post #5 of 9 Old 07-15-2010, 01:09 PM Thread Starter
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Here's a picture from the bottom.


Here's a picture from the cab.


Here's a picture where you can see where the shifter goes up into the cab.


Here's a picture of the linkage connection.


Here's the knob handle, if this helps anybody...


Here's the overall truck.


For all the pictures, the truck was in 2H.

Thanks in advance for any and all help.
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post #6 of 9 Old 07-15-2010, 11:43 PM Thread Starter
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I first clipped the zip ties and removed the rubber boots. I then lubricated everything, and with the help of a hammer and some other violent negotiations, got it to push down properly. Now it will shift to 4 Low and I drove it and N and 4Low work perfectly.

Now, though, I can shift it back to 4High, but when I want to go to 2High, I have to pull up toward the sky on the knob. Does anybody else have this problem? Any easy ways to fix it? It doesn't affect operation hardly, so I'm not too worried about it, but it would be nice if it worked properly.
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post #7 of 9 Old 07-16-2010, 04:33 AM
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Spray the assembly with penetrating lube, and tap it down with a hammer and pull it back up multiple times and it should loosen up. It may take some work, but it will free itself up.

-John
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post #8 of 9 Old 07-16-2010, 06:00 PM Thread Starter
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I let it soak overnight and it works perfectly now. Thank you for the help, guys.
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post #9 of 9 Old 07-30-2010, 06:39 PM
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Either trying to loosen up or setting a plaster to take out a broken nut, soaking it overnight is the best method.

Last edited by onseytote; 08-02-2010 at 09:32 AM.
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