93 Manual 4WD Linkage Not Connected...

[smallk]

I just bought a used '93 sport with the manual trans. The other day I thought I should give the the 4x4 a try; I locked the hubs, shifted to neutral and when I grabbed hold of the 4wd shifter it felt a little loose and it didn't feel like anything was shifting into gear. So I crawled under and had a look at the 4x4 unit and found a bit of a puzzler; the shifter isn't connected to anything! Puzzling still is the lack of any linkage whatsoever, aka there is nothing to connect! So I am wondering if somewhere in this explorer's shady past could it have been possible to throw an automatic 4wd unit on. I have no clue why anyone would want to do it, but no linkage does kinda imply that. Any information on this would be greatly appreciated.

 

[Bronco638]

Or, the transfer case doesn't work in 4WD and in an effort to avoid the "temptation" to shift the t-case, the previous owner removed the linkage. Perhaps you have an electric t-case in place of the manual one.

Does the slot/hole for the t-case look factory? The factory install would have the thick (1/4") 'gate' installed (to keep from over shifting from 4Hi to N).
And, what parts of the linkage DO you have? Sounds like you're missing the short lever from the shift fork to the shift shaft on the case itself. This arm is about 4" long and has a rectangular slot on one end (for the t-case shift shaft) and a pin on the other end (to interface with the shift fork). However, if there's no shift shaft (electric version), then you'll have to swap that for a manual.

 

[smallk]

The only linkage that is present is the arm attached to the shifter itself (the one with the interfacing slot).if you go to the post that describes electric shift motor rebuild (http://www.explorerforum.com/forums/showthread.php?t=123542) third picture down is kinda what the back end of the transfer case looks like (no shift motor just a gaping hole with 2h-4h-4l, I don't think there were bolt holes to mount one either). Does the manual t-case have the 2h-4h-4l circular layout with the hole in the center, or is that a dead sign of an automatic unit.thanks

 

[Bronco638]

Yeah, the BW1354 manual and electric versions have the same housing.

OK, you have the shift handle that protrudes into the passenger compartment. That should include the two prong 'fork' on the underside of the truck.

Now, check the front side of the t-case. As I mentioned, it sounds like you're missing the short shifter arm that bolts to the shift shaft on the t-case itself. This arm will have a pin on one end. A circular plastic bushing rides on that pin. The bushing slides between the fork "fingers". On the t-case end is a rectangular slot. The slot goes over the retangular shift shaft which has a threaded end. A nut will hold the short shift arm to the shift shaft.