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- Joined
- Aug 19, 2001
- Messages
- 10,754
- Reaction score
- 583
- Points
- 113
- Location
- So. Calif (SFV)
- Vehicle Year
- 1990
- Make / Model
- Bronco II
- Engine Type
- 2.9 V6
- Engine Size
- 2.9L V6
- Transmission
- Manual
- 2WD / 4WD
- 4WD
- Tire Size
- 35x12.50R15
I don`t have too many pics, but they`re not really needed... Here`s what I did....First, I tried all the fix ideas on the site including the shift motor rebuild and it still did not work.(still got the repeated clicking noise followed by the flashing lights) so I felt I had nothing to lose by tearing open the blue cap. I used a small flathead screwdriver to break away the tapered plastic seal.( not too much, just enough to seperate the two halves) Once seperated, pull the contact disk out and you will find the worn spots where it has been in the 2 hi position for most of the trucks life.
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Take a dremmel tool or a file and smooth out the havoc you caused with your screwdiver on the housing.Clean all the contact points with alcohol and Q-tips. Use light pressure with your small flathead screwdriver and bend all four drag fingers back into the position where they will make firm contact with the position sensor disk, but use care not to over do it. If you do, the fingers will dig into the disk, killing the fingers and making deeper grooves that caused the problem in the first place. Use good quality dielectric grease and lubricate the disk and fingers. Put the wheel back into the cup trying to keep it in the 2 hi position,( not too important though, since your shift motor took a dump in 2 hi the blue cap can only be put back on the same way), put a light coat of grease on the rubber o-rings that seal the cap and put the top back on. I used a few drops of super glue to hold it in place during the re install. Put it all back together and throw it back in to your truck. Hopefully this will fix your problem. My T-case has worked flawlessly for quite some time after doing this and I`m baffled why no one else has tried it yet. Good luck and let me know how it works.
(Post originally made by "roxy 33")
user posted image
user posted image
user posted image
user posted image
Take a dremmel tool or a file and smooth out the havoc you caused with your screwdiver on the housing.Clean all the contact points with alcohol and Q-tips. Use light pressure with your small flathead screwdriver and bend all four drag fingers back into the position where they will make firm contact with the position sensor disk, but use care not to over do it. If you do, the fingers will dig into the disk, killing the fingers and making deeper grooves that caused the problem in the first place. Use good quality dielectric grease and lubricate the disk and fingers. Put the wheel back into the cup trying to keep it in the 2 hi position,( not too important though, since your shift motor took a dump in 2 hi the blue cap can only be put back on the same way), put a light coat of grease on the rubber o-rings that seal the cap and put the top back on. I used a few drops of super glue to hold it in place during the re install. Put it all back together and throw it back in to your truck. Hopefully this will fix your problem. My T-case has worked flawlessly for quite some time after doing this and I`m baffled why no one else has tried it yet. Good luck and let me know how it works.
(Post originally made by "roxy 33")
