Question about 2003 Ford F150 Regular Cab

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Possible fork damage in 4x4

What do you have remove to get to the fork?

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  • yadayada
    yadayada May 11, 2010

    what are you refering to by the fork, not a part i am fam with

  • Anonymous Mar 28, 2014

    i can't get out the old shifting forks to put the new.punched the pins but still can't get them out. do you drive them out through the ends of the cover plate?



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I'm not familiar with ford ,but if it is like GM or Jeep,there is an actuator on the axle housing.remove this andthe shift fork should be attatched to it.

Posted on Jan 19, 2009


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  1. Raise and support the vehicle safely. Position a drain pan under the shift motor.
  2. Disconnect the vacuum harness. Remove the housing attaching bolts. Remove the housing, motor and shift fork as a unit. Mark the shift fork for installation reference.
  3. Rotate the shift motor and remove the shift fork and motor retaining snaprings. Remove the shift motor from the housing.

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Fig. Fig. 1: Shift motor and housing removal

  1. Remove the O-ring seal and discard.

To install:
  1. Add 5 oz. of gear lubricant to the axle through the shift motor housing opening.
  2. Install a replacement O-ring seal on the shift motor. Install the motor in the housing with the retaining snaprings and slide the shift fork onto the shaft with the reference marks aligned.
  3. Engage the shift fork with the shift collar and install the attaching bolts. Tighten to 101 inch lbs. (137 Nm).
  4. Connect the vacuum harness, lower the vehicle and road test.
  5. It could be damaged extreme 4x4 replaced one with a heavy duty unit

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There are two parts to the 4X4 engagement. One part is the transfer case actually shifting into four wheel, and the second part is the front axle engaging.
If you have a manual shift, as long as the linkage is working, the transfer case is engaged and the problem will be in the front axle. If you have an electronic shift, you can determine if the transfer case is engaged by the lights on the switch. If the switch lighting is correct, the problem is in the front axle. If the lights are not correct, reset the encoder motor module (located behind the ash tray, listen for the clicking when you press the 4X4 button) by disconnecting it for a few seconds and reconnecting it. If this doesn't correct the problem, it's probably the encoder motor. (located on the driver's side of the transfer case) After you change the encoder motor you may have to reset the module again.

Front axle-verify the servo (either air or electric) is operating the clutch fork in the axle by removing the cable end in the axle. Sometimes it's a small shear spring that breaks. Otherwise, usually it's the shim kit and/or fork that need to be replaced. Parts are cheap, but it takes some time because you have a lot of parts to remove.

Jan 03, 2009 | 1996 GMC Sonoma

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