NP271 Transfer Case issues (4L stuck)

This past weekend we went on our first outing of the year. Everything was good until we were pulling out of the sand to the main road. When I went to unlock my hubs and take it out of 4L, it didn't want to come out. After fighting with it for 5 minutes, it finally came out. It took a little rolling to synchronize the gears. I can't imagine the fun driving in "2L" for the 45 miles home. I use 4L (and 2L) all the time to maneuver trailers around and when we go into the sandy beaches to park the WC.

After a little research, I found out the problem is with the range shift fork pads that move the sleeve to engage the low range planetary. It binds up when the pads fall off. Fortunately, I can still drive in 2H now until I have time to tear it apart. I've got the parts on order. It's a kit to update the problem. They machined an oil galley into the sleeve and mainshaft so the fork oils better. It'll be here today. The dealer quoted me $500 for the parts at my cost. The biggest cost is the darn mainshaft. My brother diagnosed it for me as he works in the service department. He has seen this problem a few times. From what I researched, the newer trucks have the updated parts.

I need to go buy a 1-1/2" socket to get the flange off the main shaft. Other than that, it's standard garage tools and patience.

Can your brother get the plugs that plug into the transfer case.

I can't prove it but I think the transmission guy broke it when they had it out.

I can push it in like I'm plugging it together but I guess a tab or something is broken to keep it locked together.

I'm not sure what the connectors look like, but could you use a zip tie to lock the two connectors together? I know they have a connector catalog with a lot of connectors, but I'd have to look up what the NP273 uses and see if they have it available. But I know they use zip ties to keep the under valve cover harness together. I'll take a look at it and get back to you.

On a side note, I returned all the parts as I had all the updates for lubrication. I just replaced the pads and the fork just to be safe. It's still quirky, but livable. I really think my transmission drags a little bit when it's in neutral just enough to put a small load on the input shaft and prevent the gears from meshing. After the whole exercise I think there was absolutely nothing wrong internally with my transfer case. It's hit and miss but it seems to shift normally about 70% of the time. The other times, I put it in park and that stops the input shaft so I can get it out of 4L. The cool thing about the manual case is the only wiring is for the shift light on the dash. You don't need to have your foot on the brake or in neutral to shift.

Is it this one? There are two. One for the motor (two wire?) and the 6 pin control.

http://www.p71interceptor.com/motorcraftpigtails/Wiring_Pigtails_Illustration_Guide.pdf

Open up page 69 of 115 and look at WPT-228. You can order the pigtail with the connector and simply remove the retaining pin and just put the old pins in the new connector. This is a neat catalog if you ever need to fix wiring.

That pretty much looks like it,,,, I like the idea of ordering a new one though if its not to much. I'll look all that up and see.

I wish mine was manual shift with manual hubs. I'd like to change my hubs to manual anyway. How much of a B' is that to do ?

IIRC, The pigtails are in the $10-20 range.

It's easy to change the hubs to aftermarket units that are unlocked or locked settings. I know Warn has options.

Putting new hubs on is a deal, wait till your wheel bearing go out then do it. Fords have a all in one unit with bearings. My driver side went out and it was about 400.00 for me to do it. So the next time one of my frout bearings go out we will put Warn hubs on that FREE Wheel. They make a hub that will go on but not free wheel. Ford has a Auto and lock setting, any time you switch to 4wheel drive with Fords you are locked in, in free wheel you must stop and get out to lock in the hubs. With free wheel you can put it in 4 low and not lock in the hubs and use your lower gears without the front lock in. With my 2001 Ford I can not do this. I do not like the all in one bearings so the next time I will change that to the old stile, you can hand pack the bearings your self

So you can't get the manual locking hubs that would fit the stock hubs ?

When I was into four wheel drive vehicles, (Land rovers) I am glad that they where mechanical not electric. Good old fashioned dog clutch
Sean.