Transfer case 2H but driveline won't disengage

[91 4.0L 4x4]

1991 Ranger XLT 4.0L 4x4 5 spd. Manual

Scenario:

- Pulled electric shift motor for benchtop rebuild (bump stop replace).
- Tested motor both directions, reinstalled.
- Successful shift into 4H & back to 2H. Then successfully 2H to 4H to 4L.
- While attempting disengage from 4L to 4H, shift motor stops working.
- Removed shift motor, manually returned to 2H. Triangular indicator nib on T-case is at 2H, but front driveline will not disengage. Pulled auto-hubs, put them right back on (wheels spin freely both directions = hubs disengaged) and reversed for 20+ ft, of course. Front driveline stays engaged and forward motion starts hub engagement keeping me in 4WD.

Questions:

- Must the electric shift motor be in place in order for the T-case to return to 2H (electrical continuity, speed sensor)?
- How common is it for the problem to be the position selector (triangular nib) on the T-case? Its action feels correct, O-ring seems fine.

Notes:

- Long ago I detached what I believe they call the neutral safety switch (so I can start without foot on clutch) any chance this matters?

- Jerks violently with slight turns on dry road (told thats "normal").

- Unlike in the past, right auto-hub allowed big splined stub and ring to slide out into my hand while pieces in left hub were retained, but i dont care much because...
- I'm converting to manual Warn "jeep" hubs but first things first, I need to return to 2H.

Gimme 2H so I can drive, solve my shift motor and convert to manual hubs!
If you have any advice PLEASE respond today!

Thanks much!

 

[ThatGuy]

Get someone you trust and put the trans in neutral. Rock truck back and forth while you are under it and shift from 4hi to 2hi. You might not be engaging 2hi completely. When you get in 2hi you should be able to turn front driveshaft by hand.

 

[91 4.0L 4x4]

Still won't disengage...

Thanks for the reply.
Tried that, it didn't work.

I have lifted all four off the ground to eliminate any fore/aft driveline resistance, manually shifted the T-case selector nib to 4L (in neutral, brake has been pressed), then shifted it again to 4H & then to 2H, rolling the driveline reverse for at least 20 ft.

T-case indicates 2H position but will not give up the front driveshaft.
How can I get back to 2WD?

Pulling the front drive shaft and letting the T-case yoke just spin would feel like species regression to me.

Any other ideas out there?

Thanks, this forum is quite a resource.

 

[91 4.0L 4x4]

Still stuck in 4WD...

Still stuck in 4WD as stated above.

Anyone know if I risk any damage by just pulling out the front driveline and driving it that way? I imagine the T-case yoke will just keep spinning, but will this damage the T-case or transmission in any way?

Any advice is much appreciated.

 

[91 4.0L 4x4]

Half-ass solution to no disengage

1991 Ranger XLT 4.0L 4x4

My goal was to repair the rubber bump stop in the shift motor and replace the auto-hubs with Warn's P/N 37780 "Jeep" manual locking hubs which are stronger than Warn's P/N 29071 "Ford" manual locking hubs. Both of these are remarkably easy jobs.
My problem is that after my rebuild of the shift motor it still has resistance slowing it (assembly tightness?) and worse, my T-case doesn't seem to recognize the 2H position. I guess my issue is now with the T-case innards.

Sooo...I pulled the front driveshaft out so I could drive the truck. The yoke spins at the transmission, but no more front axle engagement.

I wonder: Since the T-case is still in 4H, am I in a reduced gear in the back?
Whats the most common problem with this Transfer case?
Thanks to all who chimed in on this, "we're all in this together".

 

[ThatGuy]

No. You dont have a reduction in hi range. The only way I see it is you're either not shifting the t case to 2hi or your hubs aren't letting go. Pull the hubs and see if you can get it in 2hi. If you can then its a problem with the hubs. If not then you have something wrong with the case. Pick up a used motor at the junkyard and see if it shifts better. If you cant by hand though its an internal case problem.