We have replaced the clutch disk, pressure plate, release bearing and the release fork.
After it's all back together the transfer case pops out of 2 wheel high, 4 wheel high, and 4 wheel low. Everything else seems to be working alright.
The transfer case is a Borg-Warner 1356. Any and all of your thoughts would be a major help.

Thanks,
Steve

1993
Ford F-150
Regular Cab
4x4
4.9L

 

Check to make sure you've gotten everything back together right and that you don't have a broken or bad motormount(s) or tranny mount. Also check to see that your t-case is engaging fully. If you bent a linkage or some thing it may not be getting the whole way in. I'd also check for contact on some thing its not supposed to. Just some ideas to start with.

 

Thank you so much for the advise. I have the linkage dis-connected from the shifter to the lever on the case. The lever on the case does seem to go all the way into position. I have been told that the transfer case would not blow all three gears at once, you would only loose say 2 wheel high, not 4 wheel high and 4 wheel low.
Thanks again for the advise.

Steve

 

I had the same problem, turned out to be the front shift fork in the t-case was wearing thin and not holding all the way in gear, this allowed it to jump out of gear no matter what gear I had it in. It's happened on two different t-cases for me. That shift fork is $28 and easy to fix
If thats the problem, hope its just linkage that needs adjusting

 

Would it matter if the linkage was disconnected? I tried disconnecting the bar that runs from the shifter assembly to the tab on the transfer case itself. Thank you very much for your help. I am still working on it and I will let you know what I find.

Thanks,
Steve

 

ccnseven, I am pretty sure that you are correct. My fork was not wearing thin, it is actual twisting on the tabs at the end portion of the fork. I will get the new fork in the morning and see what happens from there, god I hope it fixes the problem.

Thanks,
Steve

 

Worked for me but I pulled and went through the t-case 3 times before I figured it out

 

CCNSEVEN, you were 110% correct. It was the shift fork in the t-case. It is running very good now, thank you very much for your help. It would have taken me a very long time to figure it out on my own.

Steve

 

I'm glad you got it back together, makes ya feel better bout youre rig when its workin right.