The switch I checked is on the front, driver's side of the transfer case. The fuses were fine, which was the first thing I checked. I haven't looked at the vacum yet, since it looks to be the switch.

Another question for you all. According to the Haynes manual, they suggest using A/T fluid in the transfer case and manual transmission. I have always used gear lube in manual transmission's. I want to change the fluid in each of these, and I am wondering if the Haynes manual is correct. Any thoughts?

Also, what am I going to get involved with, if I want to replace the tailshaft gasket on my transfer case. It has a very slow drip, not even enough to make a mark on the ground and the back of the Transfer case is bearly wet. I tried to tighten up the bolts, but they won't budge. I was thinking of trying Lucas transmission fix, if I should really use A/T fluid in the transfer case. I was hoping that might take care of the drip. I have used it in the past with in similiar situations, with good results.

 

Also, just wanted to let you know that I was able to order the part from a local Ford dealer. I should have it by noon on Friday. That was a lot quicker then I expected. $31.98 for the switch. I will let you know how I make out.

 

I can't thank you guys enough!!! The 4 wheel drive works like a charm. I drained the transmission and tranfer case fluid, put in a new transfer case rear seal and pulled the tailshaft off and put silicone on it. The leak is gone. I put the new switch in, and everything is working perfectly!!! I love having 4 wheel drive again. I am ready for the winter. In case anyone else runs into the same problem, the Motorcraft part number for the switch is SW-6251 or 4L3Z-7E440-AB. It is actually called on oil switch. It cost $31.98 from the Ford dealer.

I also changed the differential fluid in the rear and the front. With the new pads and rotor I just put on, the truck is running great. Thanks again for all your help!!!!

 

My 4x4 doesnt work anymore so im still doing some research. The switch that you replaced, are you talking about the one under the front of the truck behind a black cover where the vacuum lines go to? I wonder if thats the same problem im having. I can move that little switch thing by hand to engage 4x4, but the vacuum wont. Help.
I also have the manual 4x4.
Thank you.

 

The switch I replaced was on the transfer case. My vacuum was fine, so I didn't mess with it. I would read this post, and ask the guys that helped me out. They certainly seem to know what they are doing. They diagnosed my problem pretty quick.

 

Ok, thanks!!

 

After some more diagnosing, I think we figured it out. I gotta stop at the dealer tomorrow and get a 4x4 indicator switch, I think thats what you got, right?

 

That is what I thought it was called, but it is actually called an oil switch.
Here is info from a previous post I listed.
"In case anyone else runs into the same problem, the Motorcraft part number for the switch is SW-6251 or 4L3Z-7E440-AB. It is actually called an oil switch. It cost $31.98 from the Ford dealer."

It is on the front driver side of the transfer case. It is only on the manual shift 4 wheel drive trucks. I hope this helps.

 

I was just at the ford dealer and they didnt know what I was talking about. So I came back home to pick up my chilton book with the diagram and to jot down your part numbers. Thanks a lot!

 

Ok, is this the part you replaced too? Here's what it looks like if anyone cares to see it.

 

That is the same part I just put in. It wasy a very easy install. Let us know how you make out.

 

Will do. Probly wont do it till this weekend though. Thanks for your tips etc.

 

Thanks for posting you fix si83gt!! Now my 4x4 works like a charm again!!

 

Glad to see you got it fixed. Happy 4 wheeling.

 

First of all let me say that this is the 1st 4x4 I have ever had, so I could just be ignorant.
My 97 F150 4x4 has a 4.6 litre and the Automatic transmission. I just recently purchased the truck from a lot and had an opportunity to test out the 4x4 today. It seemed to shift just fine into 4L, 4H, and 2H. We drove on the beach for about 2 miles, going between 2wd and 4H.
Once we finished playing on the beach and wanted to switch back to 2wd, I shifted the 4x4 back into nuetral (where it was when I bought the truck). We drove about 100 feet and it felt like the tranny slipped to nuetral. I noticed that the 4x4 shifter had moved, so I figured I didn't get it locked into nuetral and I tried again. It really did not want to go into nuetral and stay.
What could I be doing wrong? Now I know the smart***es will have plenty to say about my ignorance, but I hope that someone could help me out here.