Transfer case slips out of 4x4

[GDHale]

I have a 1993 bronco with electric shift. Shifts into 4x4 then while driving it slips out of 4x4 and into neutral. Press button and goes back into 4x4. To test the electronics, I put it in 4x4 and unplugged the shift motor then drove it. It slipped out of 4x4 into neutral. Plugged the shift motor back in and put it in 2x4 and drove home. Years ago, it used to slip into neutral when driving in 2x4

 

[Tiha]

Most likely it is a busted shift fork inside the transfercase I believe.

With the motor off I can't imagine what else could do that.

Busted shift forks are pretty common.

 

[miesk5]

Yo GD,
WELCOME!
Recall, BW 1356 Touch-Drive Electric Shift Transfer Case in 93 Bronco & F-Series 4x4 Vehicles Safety Recall 93S65; THE TRANSFER CASES HAVE BEEN BUILT WITH THE WRONG ELECTRIC SHIFT MOTOR. THE TRANSFER CASES CAN SLIP OUT OF THE 4 X 4 HIGH GEAR POSITION DURING COASTING IN FORWARD GEARS OR WITH POWER APPLIED IN REVERSE GEAR. IF THIS OCCURS, THE VEHICLE CAN ROLL FREELY AS IF IN NEUTRAL POSITION REGARDLESS OF THE TRANSMISSION GEAR SELECTOR POSITION. THIS CANRESULT IN LOSS OF VEHICLE CONTROL AND AN ACCIDENT. REPLACE DEFECTIVE TRANSFER CASES WITH THE CORRECT VERSION.
See Recall info below.

1356 Electric Shift Troubleshooting & Repair - BEST PROCESS! @ http://web.archive.org/web/20100923...rford.org/documents/electric1356/elec1356.htm
Source: by Dustin S (Dustball, Mellow Yellow, Mr. Laser Boy)

●
Find out if speed control, if equipped, recall work is completed.
If you still have concerns about Recalls, please contact the Customer Relationship Center:
US: 800-392-3673 | CA: 800-565-3673
Note: 3673 spells "FORD" on phone keys
For the hearing- or speech-impaired: Please contact the Telecommunication Relay Service by dialing 711.
... have VIN ready.
"Summary: ON CERTAIN PICKUP TRUCKS, PASSENGER VEHICLES, SPORT UTILITY VEHICLES, AND MOTOR HOMES CHASSIS, THE SPEED CONTROL DEACTIVATION SWITCH MAY, UNDER CERTAIN CONDITIONS, LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN. THIS COULD RESULT IN AN UNDERHOOD FIRE."
See this guide by jowens1126 to confirm recall status @ 93 & 94-96 Cruise Control Recalls Repair
Note that the 93 recall is different than 94-96.

Here is the 1993 Bronco Dealer Brochure in Google Drive @ 93Bronco.pdf

1993 Bronco Dealer Training Video via silver70 @

1993 Bronco, Venezuela Commercial @

Haynes Red Manual for 80-95 Bronco & F Series @ Hanes guide 80-96 bko f series.pdf via BroncMom
Al

 

[GDHale]

Thanks for the info. I have been dealing with this for years and no one has ever had any idea. I will post what the fix was when I have it all worked out.