Welcome and Congratulations on acquiring the best year Bronco! !
As canuckistan97 advised.
"..they can sieze from lack of use..hit the shift linkage with some penetrating oil and try again..the lever should pull straight back into 4-hi." by jermil01
1356 Manual Shift Wear; miesk5 note, Figures are gone.
"...Manually shifted units usually exhibit wear on the selector shaft in two areas (figure 5). Shaft wear in any form will make the unit disengage or have very sloppy shifting. The star shaped end of the shaft where it mates with the shift cam is also prone to wear. Borg Warner released an updated shift cam with an Allen screw to tighten up the fit and retain the manual lever. Look at the section of the manual lever that rides in the case, which is also subject to wear from dirt and two dissimilar metals in close contact...Always inspect the bore of the case for excessive wear. Figure 6 shows the bore is worn over size and will no longer hold the selector shaft in position. The only way to fix this is to do some machining and sleeve the bore, or to replace the case altogether..."
Source: by Mike W @ GEARS Magazine - September 2001
4x4 Lever Operated System With Automatic Locking Hubs
"To shift from 2H to 4H: Stop the vehicle and move the transfer case shift lever straight back to the 4H position, the automatic locking hubs will engage when the vehicle is driven. When the automatic locking hubs are engaged, shifts between 2H and 4H may take place at any speed.
❑The automatic locking hubs may disengage in 2H if the vehicle’s direction is momentarily
reversed, or the vehicle is allowed to roll slightly in the opposite direction. If a grinding noise occurs when shifting from 2H to 4H while the vehicle is moving, one or both of the automatic locking hubs have been disengaged and the transfer case shift lever should be switched back to the 2H position. To shift back into 4H, stop the vehicle and move the transfer case shift lever straight back to the 4H position.
Lever Operated System With Manual Locking Hubs
To shift from 2H to 4H: Stop the vehicle and engage the manual locking hubs by turning both hub lock selector knobs clockwise to the LOCK position. Move the transfer case shift lever straight back to the 4H position. After both hubs have been turned to the LOCK position, shifts between 2H and 4H (or 4H to 2H) may take place at any speed.
*❑Do not drive the vehicle in 4H or 4L with the manual locking hubs in the FREE position.
❑Do not drive the vehicle with the left and right manual locking hubs set to different positions.
To shift from Two-Wheel Drive to 4x4: To shift into 4x4, push the 4x4 button located on the instrument panel. This shift can be done at a stop or at speeds up to 55 miles per hour (88 km/h). When the vehicle is driven, the
automatic locking hubs will engage. If the vehicle is stopped while in 4x4 and the vehicle direction is reversed from the previous direction, the automatic locking hubs will momentarily disengage and reengage. The automatic locking hubs may click as they automatically engage in the new direction." by Ford in 96 Bronco Owner's Guide, Maintenance Schedules & Parts and Accessories by Ford @ Owner Manuals | fleet.ford.com
1356 Manual Shift, No Movement or Neutral Position Tip/Saver Spacer & pic; "...Many 1987-1995 Ford F series 4x4 trucks and full size Bronco owners with 1356 manual shift transfer cases commonly complain of a "no movement" or an occasional neutral condition. This condition is usually caused by the linkage wearing the transfer case at its point of contact (1356 manual shift models only). Sonnax offers a case saver spacer 36605-01. This case saver spacer goes between the shift selector cam and the case and requires no special tools to install. The spacer moves the cam closer to the shift fork, thus preventing and/or eliminating: 1) one or both shift forks from becoming disengaged from the shift cam, 2) "slop"from the linkage caused by a worn linkage bore in front case half. This item is a specific size/thickness not commonly found in ordinary flat washers. This repair is quick, easy and a lot less expensive than repairing or replacing the case. Model: 36605-01..."
For any Bronco questions or to chat about it's planned modifications, it's better to post each seperately in Noobie Bronco Tech Questions. Flame free zone. This will get more attention and you can build up your post count to get into other sections such as Bronco and Ford Parts/Accessories (75 posts required to view).
Please fill out your Bronco Signature with year, engine size, transmission type, transfer case type (manual or electric shift), locking hub type (automatic or manual), location info & major mods such as a Lift, etc. for better responses.
From the navigation, near the upper right-hand corner, click on your avatar and then select “Account Settings” from the drop
To save you time and for better responses, please fill out your Signature with location, year, engine size, transmission type, transfer case type (manual or electric shift), locking hub type (automatic or manual) info & major mods such as a Lift, etc. .
From the navigation, near the upper right-hand corner, click on your avatar and then select “Account Settings” from the drop down menu.
From your “Account Settings” page you will then see more navigation option of the left side. Select “Signature”.
Now you can simply enter your signature information in the text editor and click save.
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