11/27/2025
1997 F150 4.6L 4WD.
COMPLAINT = Stuck in low range. Manual shift on floor Borg Warner Transfer Case: shifter feels normal, light on dash corresponds to shift lever position. Vehicle wonβt exceed 30 mph , high pitch whine sound (stuck in low)
PROBLEM = T-case pump ear where recessed into notch in case wore through allowing pump to spin broke pick up strainer tube, parts no longer lubricated, range shift fork inserts worn down no longer engaging low range hub.
FIX = Fabricated bracket with steel key to fit in groove made by pump ear, replaced range fork and hub, cleaned strainer, replaced pick up tube, cleaned/removed all metal shavings, lubed bearings, checked tolerances and reassembled.