OK, went out to look at it today one last time before trying to find someone to repair it, and it really does seem like the transmission isn't engaging the transfer case in any way, shape, or form.

For instance, with the truck in park, it will roll freely forwards and backwards and the Emerg brake has to stay on to keep the truck parked. Doesn't matter what mode the transfer case is in, 4H, 4L, 2H, or N, it does this.

In Reverse, no matter what mode the Transfer case is in, the truck will roll freely in both directions.

In ALL Drive gears, no matter what mode the Transfer case is in, the truck will still roll freely in both directions.

Again, the transfer case that WAS on the truck was simply cracked, it still drove both in Forward and Reverse, so it's NOT the transmission, somehow the transmission shaft isn't engaging the transfer case from my LIMITED knowledge of how the Transfer case works.

And yes, I did verify the shifter linkage underneath is hooked up. I even disconnected it and manually moved the shifter on the TRANSFER CASE into each gear mode (4H, 4L, 2H) to test it and still the same results.

Can someone who has had one of these apart please chime in with ideas of what might be going on? Because from the parts diagram I have, the transmission is connected STRAIGHT BACK to the rear wheels, and it doesn't appear as though there's ANY WAY the rear wheels wouldn't be connected at all times to the transmission input shaft? Or does the shift linkage in the transfer case actually allow for the Transfer Case Mainshaft (#13 in the parts diagram) to slide to where it's completely disengaged?

Would rather go into this a LITTLE educated rather than just blindly trusting someone who already has me concerned about their competency, and I can't find another shop in the area who specializes in 4x4 transmissions, the guy I used to use retired a while back. :/

Thanks, and Happy New Year!

 

Well there can be 3 things that could be possibly WRONG with your transfercase/transmission>
1. The imput shaft size is the wrong diameter in your transfercase meaning that there's just no power being sent into the case.

2. That somehow your case is stuck in neutral (even tho you can "shift" manually) best bet is to pick one front tire up in the air and "shift" in and out of 4wd- see if you can spin the air born wheel. If it spins then the case isn't infact shifting the fork but just the lever.

3. BROKEN OUTPUT SHAFT for tranny- highly unlikely

 

well if he used the wrong size input shaft he might have damaged the shaft causing it to spin freely instead of engage as intended....

Without pulling the trans we can't really go any more forward.... if you had the work done by a shop I would bring it right back.

 

Shouldn't have to pull the trans, its not that hard to drop the case (must easier in the air but not too terrible on the ground) for sure it should be up to the shop to "fix" this error- the place the transfercase came from should pay the extra labour and sending out another case.