Ford 7.3L Power Stroke (1999-2003) :: Transfer Case Motor Replacement
Aug 18, 2016
Do we need to drain the fluid to change the transfer case motor?
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Aug 18, 2016
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Ford 6.0L Power Stroke Diesel :: Procedure For Replacing Transfer Case Motor
What is the correct way to clock the transfer case so it will line up with the new transfer case shift motor. I have read that you should not clock the transfer case shift motor.
View 8 RepliesFord 7.3L Power Stroke (1999-2003) :: When To Rebuild Transfer Case / Mileage
I have this 99f250 and it has a 273f, the transmission side of the case has threads stripped so I am about to remove and retap them. While its out should I consider rebuilding this thing? 197k miles, operates decently although the rear bearing on output side is my first thought to replace from mileage only.
View 1 RepliesFord 7.3L Power Stroke (1999-2003) :: Clicking Noise Coming Just Forward Of Chain Section Of Transfer Case
I bought a 2000 Ex PSD 4x4 in september. I have refreshed the suspension in the last 4 months; leafs, shocks, etc. I developed a vibration over 50mph after I installed the suspension and have been chasing it since.
I have replaced the U Joints, professionally balanced and lubed driveshaft twice, adjusted driveshaft angle to less than 1*, replaced the flanges for the TC output and the driveshaft companion flange. I have not touched the diff, but there is no decernable play in the pinion or leaks. Also, I removed the rear housing of the TC and replaced the output needle bearing and seal 2 weeks ago.
The output of the TC still has 1/4" play and a clicking noise coming just forward of the chain section of the TC. I assume the play is coming from other bearings on the main shaft in the TC.
I am about to purchase a remanufactured TC, but before I do, I need a reality check. Is it possible there is damage to the output bearing of the Transmission or something else?
I don't want to buy a TC to put in and experience a TC failure again in a short time. It doesn't make sense to me that there would still be so much play after changing the output shaft needle bearing of the TC if the TC main shaft is supported not just from the TC bearings but the output of the transmission unless there was possible play in the output of the transmission.
Ford Super Duty (1999-2016) :: 2003 F350 Sounds Like Shifter Motor On Transfer Case Is Trying To Engage
Truck is an 03 F350 with the 6.0. It sometimes sounds like the shift motor on the transfer case is trying to engage. It has the vacuum system which is blocked off. Warn aftermarket hubs. Switch on the dash with 2wd, 4wd and 4 low.
It's kind of an off and on thing. Try to engage for a few or more seconds then nothing for awhile then repeat. It sounds like it's at the transfer case. It could very well be coming from firewall/engine bay area as well. Is there anything between the dash switch and the motor?
Ford 6.0L Power Stroke Diesel :: 2003 - Torque Shift Leak By Spacer To Transfer Case
I have a 03 Excursion 6.0 that just developed a transmission leak between the transmission and transfer case. It appears to be the transmission because the transfer case fluid is at the top. I started to notice transmission fluid leaking in my driveway. I have not had any driving issues with the transmission but I am not driving until I correct the problem. If this is the rear transmission seal, how had is it to change this seal? Must I remove the spacer between the transfer case and 5r110 tranny? Any special tools needed?
My temps have stayed at or below 150 if I recall. My fluid is slightly low in the transmission at about 134 operating temperature. The fluid is clean, red and has no burnt odor. My transfer case is topped off. Fluid ran out the fill plug when I removed it.
There is an aluminum square spacer than necks down. It is about 6" long between the transmission output on the excursion and the transfer case. The leak I see is where that spacer meets the transfer case. I see enough for the fluid to leak onto the cross member and to the driveway. I estimate that I have lost less than a 1/2 quart of fluid over a couple weeks.
Ford Super Duty (1999-2016) :: 2004 - Changing Shift Motor - Transfer Case Stuck Due To Broken Bolt?
I'm in the process of changing my shift motor on my 04 f350. I can't get it off because of a broken bolt. The previous owner must have done this before, and snapped the head and some of the shaft off, so it's basically an alignment pin that's recessed into the hole on the motor. For some reason it's holding the motor on, even though I don't think the hole is threaded. Any way to get it off. I'm thinking that taking a MAP gas torch to the casting on the motor may be my best bet.
View 8 RepliesFord Excursion :: Transfer Case Shift Motor Change
My TC motor picked today of course with the snow to go bad. Luckily I hobbled to advance right as they were about to close and got one. I laid in the snow and changed it. Needless to say I got soaked beyond belief. Anyways now it changes in and out well but still seems way to loose in the rear. Not sure if something else is malfunctioning or if these things are like that. Right now I don't feel nearly as safe as I did in my expedition and that was without even using 4hi or low just the A4WD. The excursion is sliding everywhere. My tires have great tread but are highway tires so maybe that's the issue. They are Dura Grapplers. I'm going to try throwing some weight in the rear to maybe gain some traction.
View 2 RepliesFord 7.3L Power Stroke (1999-2003) :: After Wiper Motor Replacement Some Electrical System Won't Work?
I just replaced my Wiper motor last week and noticed something strange. For the last year or so when I turn on the key to start the truck, once in a while my radio, gauges, and other electricals such as windows wouldn't work for a bit, anywhere from a couple seconds to maybe as much as a couple minutes. Since my wiper motor was on the fritz, I pulled the fuse and the radio,gauges,ect. wouldn't work until the WTS light went out, then everything worked just fine, even after I started the truck and the glow plugs come back on.Since I replaced the motor everything works as soon as i turn the key. Coincidence? Or could one of the internal relays on the motor being stuck cause that?
View 5 RepliesFord Excursion :: Transfer Case Input / Front Seal Replacement
Noticed some fluid on the bottom of the Ex a few months ago and have been watching it since. Drained and refilled with the XL-12 fluid at the time and based on what I can see the likely culprit is the input seal on the transfer case. I have searched high and low both here and via the almighty google with little info to be found. Is it simply remove transfer case, replace input seal, reseal case connection, and refill?
View 2 RepliesFord Super Duty (1999-2016) :: 2003 F350 - No Power To Transfer Shift Motor
I have a 03 f 350 6.0. My 4x4 wont engage. I checked my fuses all are good except 31 no power. Is this the culprit?. I get power at the 6pin pig tail on shift motor, but the 2pin pig tail doesn't get any power at all. I pulled shift motor off manually put power on it and it works. I also replaced both 30amp relays under hood...
View 1 RepliesFord F-150 - 1997-2003 :: 1999 - Manual Shift Transfer Case / 4x4 Only Engages In Reverse
just bought the truck first time out hit some snow and it was not engaging low or high range, but I noticed that when I was backing up it was engaged again works in high and low range, i had to reverse about a mile up the road but it worked ? 99 4.2 standard with manual shift transfer case....
View 1 RepliesFord Super Duty (1999-2016) :: 2001 F250 - Power Feed To Transfer Case Relays
2001 F250, 7.3L ... After much diagnosis, I've found that the 4 positive feeds to the transfer case relay base have no power to them. The fuse that feeds them (#17 CJB) is fine and when I jump from the fuse hot side directly to the transfer case motor contacts on the relay base, it shifts fine. As far as I can tell, there is only one wire leading from that fuse so there must be a junction block somewhere that splits it into the 4 wires that feed the relay block. I've looked underneath and found nothing. How the 1 wire gets split into 4? On diagrams this junction point is labeled, but I don't know where to find that.
View 2 RepliesFord Excursion :: 2003 - Transfer Case Not Engaging
2003 ex 6.0 limited....300000 miles ...Automatic.Merry Christmas to all.My Transfer case will not shift into 4wd . Dash light for 4wd high and low works .I get no power to transfer case 2pin connector when key turned on.Also fuses 19,27,31,33,34,45,111 are all good when checked with meter.I also swapped 2 relays in engine compartment and no change.4 WD Switch on dash has power on Green/red wire I think it is for dash light and not for operation.
View 13 RepliesFord - Explorer :: 2003 - Transfer Case Diagram
I bought a new to me 03 explorer 4.6 tow package XLT 136000mi. Rebuilt aamco trans with 10k on it. Been checking it over before i put it on the road.. No 4x4 but the button lites work and i got into low range once. (Had a hell of a time getting back to high but eventually it did). Question is if there is 12v at the brown wire on the TC the case should be fully locked? I figure when i check it if there is not 12v at the brown wire in 4x4 high i could apply 12v directly with a jumper wire to see if the case locks to 4x4. Am I correct?
View 2 RepliesFord 7.3L Power Stroke (1999-2003) :: Oil In Air Intake Going Back - Crank Case Filter?
I own a 2003 E450 (transit bus conversion) with a 7.3L w/ California emissions. I recently noticed I have a considerable amount of oil in my air intake going back all the way to my turbo starting where the crankcase breather tube attached to the air tube. The breather seems to have some sort of filter housing that is attached to the top of the valve cover. I removed it and it appears to be fairly heavy as in if it's a filter, perhaps it's full. If I'm getting oil into my air intake from where the breather tube comes off that housing and joins in my air tube back to the turbo, could that filter or housing have gone bad? It appears to be a dealer stock item only for 225. I've saw on the web people posting "reroute kits" for the 6.0L but nothing for the 7.3. Does this part simply need replaced or could I be facing a separate issue as to why I'm getting oil in my air tube?
View 14 RepliesFord F-150 - 1997-2003 :: Speed Sensor In Transfer Case
I have a 99 f150 with a 4.2 manual with four wheel drive I need to replace the speed sensor in the transfer case it looks a lot like the one in the rear end I've called the auto parts stores and they show nothing. What sensor I can use ? I did find one on rock auto that said it was for the transfer case but after looking into there part I found it was for a automatic ...
View 1 RepliesFord F-150 - 1997-2003 :: 4x4 Light Came On Even When Transfer Case Lever In 2wd
My 97 4.6 ran fine but the 4x4 light came on even when the transfer case lever was in 2wd. Then one day it would not start. It cranked over fine but would not fire. I added fuel but it didn't work. I pulled a spark plug lead and attached a spark plug while I jumped the solenoid and cranked over the engine to visually check for a spark as I have done on older trucks. Well it cranked a couple of times and then it died and won't even crank now, I must've fried something, the batterys fine. If there is a fuse or something? What could have happened when I jumped the solenoid?
View 4 RepliesFord F-150 - 1997-2003 :: Howl Going On - Noise From Transfer Case Area
I've got sort of a howl going on, was thinking rear end, but when i jacked up the wheels and spun the driveshaft the noise seemed to come from the transfer case area. I haven't had a chance to check the fluid yet, could it be a bearing in the t-case? Its only when i'm on the gas if i let off its gone. 2001 f150 super crew 4x4
View 4 RepliesFord F-150 - 1997-2003 :: Transfer Case Engaged And Locked In 4wd While Driving At 45 Mph
97 F150 4x4 5.4L ... Just put this truck back on the road after being parked since 2008. While driving at 45 mph, transfer case engaged and is locked in 4wd lo. I did notice a pop about a minute after I started the truck. Drove approx. 5 miles. Transfer case engaged and chirped the back tires, slowed speed to about 5mph. Having it towed home. I'm thinking shift motor???
View 14 RepliesFord F-150 - 1997-2003 :: Transfer Case Output Seal Leaking?
I got a 97 f150 4x4, 4.6 and I had the shop replace the seal 3 times and it's still leaking, the seal where the driveshaft goes into the t case, I call it the slip yoke seal, they said the bushing inside looks good, there doesn't seem to be a whole lot of play in the driveshaft, it doesn't seem to leak a whole lot, I'm about ready to just forget about it and just run it, they put a seal from oreillys in, it seem to be leaking out of the bottom hole on the seal...
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