Need adjustment to keep it from popping out of 4x4 ?

1999 FORD F-250
250,000 MILES • 5.4L • AUTOMATIC
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FLAME BOY
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that's funny I looked it up on my phone and it said to put it in 4x4HI and loosen up the 2 bolts that you are pointing at in your diagram 1/2 to one full turn and hold the shifter in place while tightening the 2 bolts. I had removed the shifter and transfer case and transmission and rebuilt the transmission so when I put that shifter back in, I found out later that it would need adjustment to keep it from popping out of 4x4 so I will try this today and see if it stays in 4x4 HI and LOW. just to let you know what I have done with this truck I bought it used with about 230,000 miles on it, so the motor went out at 250,000 I had the motor and transmission rebuilt I put new brakes on it and new shocks and overload springs on the back of it and new fuel pump replaced the PCM because it when out so the truck is pretty much brand new, I also painted it red, white with blue strip down the side I had lived in Calif and had just moved to Arizona and drove the truck out here it ran Relly good. I will try to adjust it today or tomorrow whichever comes 1st and I will let you know if it stays in gear. I guess I did not let you know that I had removed transfer shifter by the way I love Arizona I have a 3-bedroom house 2.4 acres nice and quiet very much off grid I have solar and no problem with power at all propane gas and water is hauled in 500 gal water tank
Jun 17, 2026 at 1:27 PM
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FLAME BOY
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Vehicle details: 4WD / AWD

I need to know how to adjust the manual transfer case shifter I installed it, but it keeps popping out of 4x4 hi and low
Jun 18, 2026 at 1:56 AM (Merged)
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STEVE W.
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There are no adjustments on the OEM manual shifter for the T-case. It is just the lever, the lower pivot and the rod that moves the shift cam in the case. It just bolts on and connects up. If it is coming out of gear that suggests there is a problem internally to the T-Case with either the bushing in the cam pivot or a problem with a shift fork so the gears are in the wrong position. Was other work done prior to this issue?
Jun 18, 2026 at 1:56 AM (Merged)
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STRAILER
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Yep, The shift fork slides inside the transfer case is probably worn out not engaging the transfer case fully, this is why it pops out. I have included an image of what the problem is in the diagrams below. Let me know how it goes
Jun 18, 2026 at 3:38 PM
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