1990 Ford F-250 4X4
Transfer case is Warner 1345
Truck has 244,000 miles
Engine and trans have been replaced once.
The plastic gears that drive the VSS off the transfer case stripped/melted. I installed a new matched set and they stripped/melted in fifteen miles of driving.
This seems to be what leads to the transmission not shifting out of first gear.
The speedometer cable turns freely and the speedometer worked fine until the gears stripped.
After driving in stop and go traffic for fifteen miles the output shaft and U-joint yoke were too hot to touch. I was not able to measure the exact temp. My guess is that it was in excess of 300f.
My thought at this point is that the output bearing is failing and overheating the gear on the output shaft.
What is involved in working on a transfer case?
Any hints or tips before pulling it out and starting?
I have a well equipped shop and plenty of experience working on and rebuilding engines and trans in many types of equipment. I guess the fact that I never had to work on a transfer case means they don't often fail?
I'll be driving another truck that is almost identical this afternoon and I plan to feel the transfer case and output shaft/yoke to see hot warm they feel.