Ok I have a 1971 Ford F-250 with the fuel injected 460, A4OD trans, and a Borg Warner 13-56 manual shift t/c out of a 1990 F- 350, with Dana 60 front and rear. My drama is that when I went to install the front driveshaft, the trans x-member is in direct line with the t/c output shaft. Is there an easy solution or am I still fabricating? Other problem is when placed in 4 low, the trans shifts extremely late but in 2hi and 4hi, operation is normal. Is there a sensor or switch to tell trans that 4 low is engaged or is this normal. All my other 4wds are manual trans.

You'll probably have to box the crossmember.. a lot of problem have that problem when they lift their truck.

I'm not 100% sure, but I believe the later model truck require a Vehicle Speed Sensor in the rear diff.

The only speed sensor on the truck, is tied into the speedo cable on the tailshaft of the transfer case. Ive checked the manuals for the 1990 rig it all came out of and it shows nothing of a sensor in the diff. There is one switck on the t/c that looks like a backup light switch, but I think that is for the 4wd indicator light (not hooked up) but I may be wrong.
As for the crossmember, thats what I thought but no big deal, Ive allready came this far. Thanks for the input! :smokin:

Is there a sensor or switch to tell trans that 4 low is engaged or is this normal. All my other 4wds are manual trans.

Nah, there's no sensor, that case is all mechanical. Yeah, there's a two-wire? output up front for the 4wd light on the dash. In theory this should also shut off the RABS, as RABS was supposed to be disabled in 4wd. I've never cared to check. Not applicable to your older truck.

There should also be a VSS on the tailshaft housing of the t-case, this is just a couple of wires that are on top of the speedo gear basically. You don't need them, don't worry about them, and they certainly don't tell the t-case to do anything.

As for your problem, here's the deal: 2hi and 4hi use the same place in the planetary. When you pull the lever back to 4hi, all it does is engage a collar which engages the chain................the chain is now powered from the rear output and it sends power to the front output. Simple.

But, when you go to 4lo, it moves what I'll call a "spur gear" to a different spot within the planetary, thus generating gear reduction. This is your issue I'd say. And it's almost surely a worn shift fork. Go thru the pics here:
http://www.superford.org/vehicles/registry/detail.php?id=139&s=13379#content

Here's a short preview:
http://www.superford.org/getfile/78941/fullsize/BW1356-2%20022.jpg

http://www.superford.org/getfile/78955/fullsize/BW1356-2%20028.jpg

http://www.superford.org/getfile/78956/fullsize/BW1356-2%20030.jpg

http://www.superford.org/getfile/81889/fullsize/BW1356-2%20063.jpg

Did you connect the wires that go to the T-case switch up? It tells the ECM when the T-case is in 4Lo. Then the ECM gives the trans a diffrent shift RPM.

I have a question how did you fit the t-case between the frame rails on your 71? Did you have notch the frame? I have a 73 crew cab that has the old stright frame like you have and I am in the process of putting a 97 460 in it. I havent installed the engine yet but when I measure it it looks like the t-case will hit the frame on the drivers side.
THX Leadmic

I think you have located my problem! I guess I snipped too many wires or something. As for the transfer case, it does fit with no notching of the frame. Thank you for the input.