91 ranger transfer case wont hold 4 hi

[theAntihero]

my manual transfer case has decided it wont hold 4 hi, i can shift it into it but it slowly pops back out. 4 low locks in and holds just fine.

Any ideas?

 

[RonD]

The Shift motor has a Contact Wheel in the gear box than rotates when the motor turns the transfer case shift rod.
This Contact Wheel and its 6 contacts "tell" the Shift module what position the transfer case is in.

Pictures here: http://www.explorerforum.com/forums/index.php?threads/how-to-rebuild-4x4-shift-motor.123542/

When you change from 2WD to 4high the Shift module powers up the shift motor and turns it counter clockwise until the CONTACTS are in the correct position for 4high
It does the same for 4low, and for 2WD it turns shift motor Clockwise until CONTACTS are in correct position for 2WD

It could be the contact wheel/contacts are dirty and just need to be cleaned, i.e. shift module "thinks" it is in 4high fully when it isn't.

And it could be the shift rod mechanism inside the transfer case is at fault.
With shift motor removed you can manually shift into 4high, use a pair of vise grips, and then tie them off so shifter stays put.
Then go for a drive, if it still pops out then you will need to get into transfer case, if it stays in 4high then rebuild and clean shift motor

 

[alwaysFlOoReD]

@RonD He doesn't have a shift motor. It's manual.

 

[rangerenthiusiast]

@RonD He doesn't have a shift motor. It's manual.

Manual on a ’91? I have a ’92 and it’s auto.

EDIT - Sorry, just re-read the thread. Good advice from RonD for those with autos though. Sorry, Antihero, and good luck with her.

 

[fastpakr]

Sounds like a good time to start with adjusting the shift linkage. I wonder if it's just barely engaging into 4H.

 

[85_Ranger4x4]

My linkage came loose on the transmission and it shifted funny too. Hard to find neutral and wouldn't hold 4hi (never use 4lo) so you might check that out.

There are also plastic bushings at both privet points that can wear and degrade too.

 

[theAntihero]

Linkage is probably a good place to start, thanks for the help guys

 

[RonD]

@RonD He doesn't have a shift motor. It's manual.

But he only mentioned it right up front................I am an idiot

 

[rangerenthiusiast]

But he only mentioned it right up front................I am an idiot

If that is so, then I must join you in the Brotherhood of Idiocy. I too missed it.