1991 F-350 7.3 non-turbo 5speed transfer case is a BW1356

[bndtransmission]

Hi guys,

This one the customer experienced neutraling issues internittantly, if you mess with the t-case it would take off again-i did verify the concern, manual 4x4 linkage and bushings are intact,
took it apart and found pump ate thru the case and mangled the bracket on it, the fork pads look ok, i see on the web there is a case saver kit that also has shims to correct the "neutraling"
issue-i cant find any directions for this kit and am wondering if any of you have experience with it? I see the worm bracket (moves the shift forks) is not very tite on the shaft where the manual
linkage attaches to it so i'm assuming it tightens this up? Thanks for any info!

[barrycole]

If you are finding the truck going neutral, then for sure it will need the linkage case saver kit which I have used may times, that I got through Sonnax. If you get the kit from Sonnax it will have the directions, or you can go to the Sonnax Web site and down load a PDF with the instructions. This kit works very well as I had may snow plow trucks through contracts, that were driven buy Tom, Dick and Harry!! LOL! Drove them like they were stolen!!

[barrycole]

I will save Rob (Tranibob) the finger tip punching on the key board. The Sonnax part # number is 36605-01

[tranibob]

Unfortunately this part is now obsolete, we don't have it anymore. I looked earlier when I read this thread and could not find anything. Just looked up that part number and it comes up as obsolete :-(

[barrycole]

Well that's a bummer!!! Worked great on these units Rob. The next way to go now is too install washers or replace the case. Its to bad the dump this, but if it is not a money maker, then it is gone.

[bndtransmission]

haha that IS a bummer, so Barry am I basically just shimming it as tight as i can get it without it binding?

[barrycole]

Brent It looks that way to me, to shim this case. Its to bad that Sonnax killed this product. Now maybe your supplier has some old stock in the warehouse, and you can get the kit. If you have to shim it yourself, don't use cheap washers. Do make your sure that you try too grind done your washers flat, so they run true with the shaft, and case. Hope all works out, Barry.

[bndtransmission]

Just an update: I never could find the "neutraling" kit that was at one time available but unfortunately no longer, nor could i find any info so I decided to just come
up with a fix of my own..I did shim the manual shaft and shifting pawl (big chunk of metal that positions the shift forks) using a washer..it helped but the "Mode"
fork could still fall out due the pawls ability to move away from the fork..I ended up removing the pin from the shift fork and welded a washer onto the very end
of the end that fits in the worm groove in the pawl-then i slid it back through the pawl and into the shift fork and installed the c-clip, it actually works great...
I have tried to upload a pic so it will make more sense but i keep getting a response "sorry, the board attachment quota has been reached" not sure what to do
but i do have a pic if anyone needs it :)

[barrycole]

Brent, Glad to hear it is fixed. I can see in my mind what you have done to repair this. Worked on many, as I said before. Maybe you should sell this repair to Sonnax. LOL! Its to bad U cant post the pictures for all to see. Maybe Dave can help in that department. Any way, glad its fixed. Barry

[dhritsko]

Already on it since first thing this AM , I like pictures . Pictures are worth a thousand words , I understand ( kinda ) what was done BUT have to see it . I will let you know , I like seeing CREATIVE minds at work . Cobbling things were always my favorite things to do .