Manual TCase Shift Range Adjustment Procedure?

[Warmblood58]

I have a '93 4x4 XLT with the 4.0liter V6. Using my four wheel drive system for the first time the other day resulted in the shift linkage pin popping out of the shift fork somehow. I was able to reorient pin to fork but it occurred to me that shift range must be out of adjustment as it feels mushy and truck is popping out of 2H now. The bushing that rides on the pin is also missing - anyone have a part number for this and a procedure for adjusting shift gates for the tcase selector? Thanks. This truck is all manual, manual tcase, hubs, and 5 speed transmission. Big thanks!

 

[adsm08]

You gotta have that bushing in place before you can do a meaningful adjustment. You might even find that you don't need to because it popped out due to the bushing being gone.

Anyway, to adjust the gate I always just loosen it up, push it as far forward into 2-HI as I can, and then knock the gate back until it touches the shifter, and tighten the bolts.

 

[Warmblood58]

You gotta have that bushing in place before you can do a meaningful adjustment. You might even find that you don't need to because it popped out due to the bushing being gone.

Anyway, to adjust the gate I always just loosen it up, push it as far forward into 2-HI as I can, and then knock the gate back until it touches the shifter, and tighten the bolts.

Thank you - loosen big bolt and small underneath to loosen slightly, yes? Any idea if Ford still has that bushing? Thanks for your help!

 

[adsm08]

Yes, loosen the big bolt about half a turn, the little one needs to go a little farther, but it's usually obvious when it is loose enough.

The last time I needed to buy one Ford still had them. It was hard to find in the catalog, but not hard to get.

 

[Warmblood58]

Thanks! Read a procedure for the Explorer where boot was pulled to expose the gate - hardest part seemed to be pulling the knob off to slip the boot off - guy claimed the knob came off suddenly while pulling on it and he shattered his windshield! Seems like the easy way is to roll the boot up to expose the boot and go from there -

 

[adsm08]

I don't even mess with the boot. Any half-decent flash light and you can see everything you need to see from below.

 

[Warmblood58]

I was looking at the gate yesterday from below - sounds good!

 

[Warmblood58]

Bushing is part 7335, 12.00 bucks for this little piece of plastic -crazy! Hopefully with the adjustment I can retain it so it does not disappear again -looks like it is trapped within fork

 

[Denisefwd93]

Rather than start a new thread, I'm going to ask you all here if that's okay.

What does it take in materials & hardware, to make linkage and handles for the manual t-case? the reason I'm asking, there are lots and lots of t-cases out there but almost none with the linkage, and shifters.

 

[Curious Hound]

That mainly depends on your layout and fabrication skills. Tools aren't that bad. A good drill, preferably a drill press would be needed. Maybe some way to bend metal. Sometimes a vice and hammer work. But a cheap hydraulic press can make it easier. You may or may not need to weld some parts. Take a look at some shift linkage pictures and you should be able to see what you need. Metal can be sourced from a local supplier or scrounged/scavenged from other places like scrap metal yards, junk yards, or picking up free metal stuff listed on Craigslist. I imagine you have at least some decent skills acquired from dabbing ductwork in your HVAC business. So your imagination and ingenuity are your limits.

This message composed solely of recycled electrons. Go green!

 

[adsm08]

It really shouldn't be that hard to make your own levers. Some flat-stock or w piece of weld plate and some round stock. Trace, cut, weld, drill, bend.

 

[Denisefwd93]

I found the thread on another site https://www.explorerforum.com/foru...shift-linkage-for-a-manual-t-case.280143/ doesn't look too difficult I really don't know where I'm headed with this, because I may still go for the shiftster, or make my own to replace the electric motor.
But there are tons of manual transfer cases out there but they're all without linkages.

 

[Warmblood58]

Ordered bushing - by the way, what holds this 12.00 piece of plastic in place?

 

[Curious Hound]

If it's plastic, it's probably formed in such a way that it snaps in place and retains itself.... Until worn out.

This message composed solely of recycled electrons. Go green!

 

[Warmblood58]

thats what I was thinking - we shall see.