1994 4.0 ohv with push button 4wd (217k miles)

Just purchased knowing something was up with the transmission (friend has a few spares if it needs replacing). The person I bought it from said his mechanic thought it was the input shaft bearing.

Truck starts up everytime flawlessly but seems to have some noise coming from the front transmission or transfer case? The shifter will go in every gear fine but when the clutch is left out there is no grab at all. As you let the clutch out the sounds good coming from the front get louder and almost vibrations too. Best way to describe it is grinding gears? Just not quite as loud and harsh as a mis-shift.

I haven't dropped the transmission yet to investigate as this is my first ranger and I'm still learning. Just wanted to get some feedback on what it could be or anything I could check for on my own to learn more.

Thanks
-Zack

 

Welcome to the forum

4th gear is not really a "gear", 1:1 ratio means it is just a direct connection between input and output shaft, so doesn't use input gear or counter shaft

So test 4th gear

If sound changes as you let up on clutch pedal then input shaft must be turning so clutch is working.

Remove shift motor on the back of the transfer case
Read here: How to: Rebuild 4X4 Shift Motor | Ford Explorer and Ford Ranger Forums - Serious Explorations

There is a picture of the transfer case shift rod, you can turn it manually
Shift rod is in/pointed at 2High in the picture
It will only turn one way from 2H, turn to 4H then 4L, between 4H and 4L (opposite 2H) is Neutral
From 4L it only turns one way, back to 2H

If transfer case is stuck in Neutral.................well truck wouldn't move


And I assume truck will just roll away if E-brake is not used or tires blocked?

 

Thanks for the reply and info Ron!

I will test only 4th and see what happens. I stopped messing with it only because the noise made me worry that maybe I could be doing more damage.

Pretty sure the clutch definitely works because you can get the truck in N with it, start it and engage and disengage the gears, something just isn't engaging to make it move.

And yes we rolled the truck onto a trailer and pushed it into my garage the day I purchased it.

 

Your 4.0l will have the M5OD-R1(M5R1) transmission which really never had many problems, used in Rangers from 1988 to 2012

So used one is not much of a gamble if trans fluid(ATF) looks OK, not black, but still red

The bell housing is not detachable so replacement must be from a 4.0l OHV or 4.0l SOHC engine, and 4WD tail shaft and housing, although you could swap yours over.
2.9l M5R1 would also fit but would be older model

Yes, the M5R1 used Automatic transmission fluid(ATF), not gear oil as most manuals used, people would put in gear oil, which could shorten the life of trans.

So truck rolls even when "in gear"?

Could be transfer case stuck in Neutral but shouldn't make any noise if that were the case, just wouldn't move with engine power
Neutral is a valid position in transfer case, often used for Flat towing(4 wheels on the ground) behind RVs, but not accessible with "stock" electric shift setup, but could be added with a kit sold by Ford.
If electric shift motor stopped working as PO was shifting from 4low to 4high then it could be "kind of" in Neutral, so might make a noise, long shot but just have to pull off the shift motor to see

 

Truck rolls with no noise from what I can tell when it's in gear, no grab or resistance from what I can't tell. I'm only pushing it a few feet forward and back by myself in the garage.

I tried starting the engine and engaging 4th gear and nothing grabs in that gear either. Although maybe there's less chattering coming from under the truck in 4th? Hard to tell...

 

Sounds like you stripped the teeth straight off one of the shafts.

 

Nope shafts look good. Friend came over tonight and tested the shift motor, we pulled everything out and we think it might be the clutch throw out bearing as it looked completely separated from the clutch disc itself.

Inside of transmission looked good, couldn't find anything internally wrong.