Dropped parts out of transfer case

Does placing it in neutral put the entire drive in neutral???? Yes . Taking the vehicle to a qualified repair shop that has a factory or professional scan tool to read code's in the transfer case control module is what you should do , you probably have no clue of the complexity of these 4X4 systems . How many buttons on the switch on the instrument panel ?
The BW 4493/4494 transfer case features a 4-button shift control switch (1) located on the instrument panel. When the vehicle has the ignition key in the RUN position, the transfer case shift control module starts monitoring the transfer case shift control switch to determine if the driver desires a new mode/gear position. At a single press of the transfer case shift control switch, the lamp of the new desired position begins flashing to inform the driver that the transfer case shift control module has received the request for a new mode/gear position. The lamp continues to flash until all shifting criteria have been met and the new mode/gear position has been reached, or has been engaged. Once the new mode/gear position is fully active, the switch indicator lamp for the new position remains ON constantly.

During normal driving situations, the transfer case operates in the 4HI mode. When the 4HI mode is selected, the transfer case shift control module sends 12-volts to an electrical motor, which is the transfer case encoder motor. This motor rotates the transfer case shift detent lever shaft which moves the shift forks and range sleeve to obtain different modes/ranges.
The BW 4493/4494 transfer case has the added feature of also providing the driver with 3 manual mode/range positions:
• 4HI - 4-Wheel Drive High Open
• 4HI Lock - 4-Wheel Drive High Locked
• 4LO Lock - 4-Wheel Drive Low Locked
The driver may choose to select any of these mode/range positions while driving the vehicle. However, the transfer case will not allow a shift into or out of 4LO Lock unless the following criteria has been met:

DTC B0790 Transfer Case Neutral Indicator Circuit Malfunction
DTC B2725 ATC Mode Switch Circuit Malfunction
The mode switch circuit consists of 5 modes. The transfer case shift control module supplies a regulated 5 volts, DC to the switch through the 5-volt regulator circuit. The current travels through the resistor of the currently pressed mode button. The current is then returned to the transfer case shift control module through the switch signal circuit.
The transfer case shift control module constantly monitors this signal voltage to determine the condition of the mode switch circuit.
When each of the modes are selected they will complete a circuit through their own specific resistor while the button is pressed. The transfer case shift control module continuously monitors the switch input to determine whether the Neutral, Differential Lock, 4HI, 4HI Lock, or 4LO Lock mode was selected by the driver.

DTC C0306 Motor A or B Circuit Malfunction
The transfer case motor is a bi-directional, permanent magnet, D.C. motor. When energized, through motor control A or motor control B, the ground is provided by the opposing motor control circuit and then grounded through the transfer case shift control module ground circuit, the motor, through a series of gears, rotates a shaft which moves the mode and range forks to shift the transfer case between the following ranges:
• 4HI
• 4HI Lock
• 4LO Lock
• Neutral
This DTC detects an open, short to voltage, or short to ground in the motor control A or motor control B circuits, or an open, or short to ground inside the motor.

DTC C0327 Encoder Circuit Malfunction
DTC C0329
DTC C0359
DTC C0550

The Borg Warner (BW) model 4493/4494 NR4 transfer case is a 2-speed, full-time 4WD, transfer case. The transfer case has an external planetary type differential, which has 2 different sets of pinion gears. The planetary differential provides a 40/60 torque split front/rear full-time. This means the front and rear propeller shafts are constantly being driven for maximum traction in all conditions. A high/low planetary carrier assembly provides the high and low ranges, which is a 6-pinion gear, sun gear, and annulus gear arrangement, giving a 2.64 low range reduction ratio in the BW 4493 and a 4:1 ratio in the BW 4494.

I guess you probably don't know what transfer case you have ?
SERVICE 4WD
Refer to
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Transfer Case Description and Operation in Transfer Case - NVG 149-NP3

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Transfer Case Description and Operation in Transfer Case - NVG 246-NP8

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Transfer Case Description and Operation in Transfer Case - NVG 261-NP2

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Transfer Case Description and Operation in Transfer Case - NVG 263-NP1

The NVG 246 EAU provides 5 modes, Auto 4WD, 4HI, 4LO, 2HI and Neutral.
The four manual mode, or range gear positions, of the NVG 261 transfer case are:
?€¢
2HI - 2 wheel drive high range

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4HI - 4 wheel drive high range, part-time

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4LO - 4 wheel drive low range, 2.72:1 gear ratio reduction

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N - Neutral, 4 wheel

The NVG 263 transfer case provides the driver with 4 manual mode/gear positions:
?€¢
2HI - 2 Wheel Drive high range

?€¢
4HI - 4 Wheel Drive high range

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4LO - 4 Wheel Drive low range

?€¢
Neutral

With the info I've given you ,you should be able too now !
There is probably a code stored somewhere !
DTC B0790 DTC B2725 DTC C0300 DTC C0305 DTC C0306 DTC C0321 DTC C0327 DTC C0359 DTC C0374 DTC C0379 DTC C0550.

A detent is a notch or notches in a part used to keep a shifter (in this case) at a certain position. Be that an automatic or stick-shift. You can imply that the shift pattern on a stick-shift has detents for each gear as the shift lever locks and slides in and out of each position for that gear to work when the clutch is released. The detents on an automatic can resemble "steps" which engage a different gear or series of gears(drive) when a certain step is locked into position by a pressure bar or pressure lever.

Sometimes the pressure bar or pressure lever is spring loaded and your hand works against that tension to select a gear or function(drive). There may be an adjustment for the spring tension, or the spring is too weak and the shift assembly must be replaced.

With electronic shift solenoids, some of the shift assembly is different than with the old-style mechanical shifter. The action may be fly by wire with electronic shifts.

I do not know what you have, so there may be differences.

Sorry ,but your best bet would be to take your vehicle to a qualified repair shop that has the diagnostic tool that check's for DTC'S - diagnostic trouble code's in the 4X4 control module . Light blinking is suppose tell you that you need to take it in for sevice ,not for you to play with something you have no idea how it work's . You probably couldn't even tell me which 4X4 system your vehicle has . Transfer Case - BW 4482-NR4
Transfer Case - NVG 246-NP8
The BW 4482 transfer case features a 3-button shift control switch located on the instrument panel. When the vehicle has the ignition key in the RUN position, the transfer case shift control module starts monitoring the transfer case shift control switch to determine if the driver desires a new mode/range position. At a single press of the transfer case shift control switch, the lamp of the new desired position will begin flashing to inform the driver that the transfer case shift control module has received the request for a new mode/range position. The lamp will continue to flash until all shifting criteria have been met and the new mode/range position has been reached, or has been engaged. Once the new mode/range position is fully active, the switch indicator lamp for the new position will remain ON constantly. In addition, the switch includes a VSES request button which sends a voltage signal to the transfer case shift control module. The transfer case shift control module in turn sends a request via the class 2 data bus to the ABS control module which controls the VSES system.

The NVG 246 EAU transfer case features a 4 button shift control switch located on the instrument panel. When the ignition key is in the RUN position, the transfer case shift control module monitors the transfer case shift control switch to determine if the driver desires a new mode/range position. At a single press of the transfer case shift control switch, the lamp of the new desired position will begin flashing to inform the driver that the transfer case shift control module has received the request for a new mode/range position. The lamp will continue to flash until all shifting criteria has been met and the new mode/range position has been reached, or has been engaged. Once the new mode/range position is fully active, the switch indicator lamp for the new position will remain ON constantly.

Looking at DTC'S is a far better place to start then crawling around on the ground looking at thing's you have no idea how there work.
DTC B0790
DTC B2725
DTC C0300
DTC C0305
DTC C0306
DTC C0321
DTC C0327
DTC C0359
DTC C0374
DTC C0379
DTC C0550
DTC B2725 ATC Mode Switch Circuit Malfunction
The range/mode switch circuit consists of 5 modes. The transfer case shift control module supplies 5 volts to the switch through the 5-volt reference circuit. The current travel through the resistor of the currently active mode. The current is then returned to the transfer case shift control module through the switch signal circuit.
The transfer case shift control module constantly monitors this signal voltage to determine the condition of the mode switch circuit.
When each of the modes are selected they complete a circuit through their own specific resistor. The transfer case shift control module continuously monitors the switch input to determine whether the Neutral, AWD, 2HI, 4HI, or 4LO mode was selected by the driver.
Transfer Case Shift Control Switch Indicator Flashes, then Returns to Previous Mode
The transfer case shift control module controls the transfer case lock solenoid. The transfer case lock solenoid is released by being energized. This is accomplished by grounding the lock solenoid control circuit during gear shifts, and in the AUTO 4WD mode. Locking action is applied when power or ground are taken away from the lock solenoid, the transfer case motor is prevented from moving. The system is capable of providing a 2HI, 4HI and 4LO lock-up without the need of additional vehicle power to hold the transfer case in these positions.
The transfer case motor is a bi-directional, permanent magnet, DC motor. When energized, through motor control A or motor control B, the ground is provided by the opposing motor control circuit and then grounded through the transfer case shift control module ground circuit, the motor, through a series of gears, rotates a shaft which moves the mode and range forks to shift the transfer case between the following ranges: 4HI, AUTO 4WD, 2HI, Neutral, and 4LO.
If there is a fault in the brake control circuit, motor control A and B circuits are shorted together, or a motor control driver is damaged in the transfer case shift control module, the transfer case shift control module goes into a shift block mode. The transfer case module will also go into shift block mode if there is a mechanical concern causing the shift lever detent shaft to bind, or the transfer case shift control module is not seeing a signal from the Park/Neutral position (PNP) switch. The shift block mode causes the mode indicator to flash for a period of time when another mode is selected. After that period of time has ended, the indicator reverts back to the previous mode selection.
Without factory service info. to guide you through a set diagnostic procedure you probably don't have a chance of fixing this yourself .

hard to explain, there is a detent,,in the case on the linkage, internal, its spring loaded, keeps pressure on the linkage, case will have to come apart.

If you look at the flange and then on the case the positions these go in as clearly visible. The bolt holes and the pins locations are different

What trans? AOD? This is 1992 F Series, all I have.

Shift Controls, Automatic Transmission The transmission shift control linkage or cable transfers the transmission operating mode from the selector lever to the transmission. The indicated transmission position on the steering column is transferred to a shift lever on the bottom of the steering column. On vehicles equipped with cable-operated shift systems, the indicated position of the transmission selector lever is transferred to the transmission through the shift cane, then to the cable, and down to the transmission manual shift lever at the transmission. On vehicles equipped with shift rod assemblies, the rod transfers the indicated transmission selector level position through a bell crank assembly to a control rod. The control rod transfers the indicated position to the transmission assembly.
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Automatic Transmission Manual Linkage Adjustments

1. With the engine stopped and the parking brake applied, place the transmission selector lever at the steering column in the D (DRIVE position) for C6 applications and in the (D) (OVERDRIVE position) for AOD and E4OD applications, and hold against the D or (D) stop by applying a three-pound force to the selector lever knob.

1. Loosen the shift rod adjusting nut at point A. Refer to the following illustrations.

1. Shift the manual lever at the transmission into the (D) (overdrive) position for E4OD, by moving the lever all the way rearward, then forward two detents.

1. With the selector lever and transmission manual lever in the(D) position, tighten the nut at point A to 17-24 Nm (12-18 ft-lb) torque. Use care to prevent motion between the stud and rod.

1. Remove the three-pound force from the steering column selector lever knob.

1. Operate the shift lever in all positions to make certain that the manual lever at the transmission is in full detent in all gear ranges. Re-adjust the linkage if required.

1. On F-Super Duty Chassis Cab and Motorhome and Commercial Chassis recheck for correct operation of the automatic transmission selector indicator (PRN(D)21). Refer to Section 11-04A, Steering Column, Shift Rod Within Tube. CAUTION: Under no circumstances will it be permissible to adjust linkage in any position other than the(D) position for E4OD applications.
   

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Automatic Transmission Shift Cable Adjustment

1. From inside the vehicle, place the column shift select lever in the DRIVE position (C6) of the OVERDRIVE (AOD and E4OD). Hang a three-pound weight on the selector lever.

1. Raise vehicle on a hoist.

1. Remove the shift cable from the transmission lever ball stud.

1. Pull down the lock tab on the shift cable body.

1. Position the transmission shift lever in the DRIVE position (C6) or the OVERDRIVE position (AOD and E4OD). This is three detents from the front-most lever position with the first position counting as one.

1. Connect the cable end fitting to the transmission lever ball stud.

1. Push up on the lock tab to lock the cable in the correctly adjusted position.

1. Lower vehicle down from hoist and remove the three-pound weight from the column shift select lever.

1. After making the adjustment, check for park engagement. Check the transmission control lever in all detent positions with the engine running to make sure correct detent/transmission actions. Readjust if necessary.

With the style of transfer case you have, just make sure your 4x4 shifter is matching
the gate to the transfer case detent, if ok, there is a mux switch sensor
mounted on top of transfer case, drivers side, replace the sensor, moisture
has ruined it, you will need to lift the vehicle up and drop the rear cross
member, use a floor jack, let hang enough to get your hand up there
and replace the sensor.

GOOD LUCK, RDJRP.

Shift Lever NOTE: Remove the shift ball only if the shift ball, boot or lever (7E067) is being replaced.
Removal

1. Raise vehicle on hoist and position suitable safety stands under vehicle.

1. Prior to removing the control lever assembly (7E069), be sure the shifter is in the 2H position.

1. Loosen (do not remove) the nut retaining the shift handle (7E067) to the control lever assembly (7E069). Remove the shift handle (7E067) from the control lever assembly (7E069).

1. Remove the vent hose (7D494) from the notch in the detent plate.

1. Remove the control rod (7A315) from the control lever assembly (7E069). CAUTION: When removing the control rod (7A315) off the control lever assembly (7E069), do so very gently so as not to damage the control lever assembly.
   

1. Loosen (do not remove) the large pivot bolt holding the control lever assembly (7E069) to the detent plate.

1. Swing the control lever assembly (7E069) out of the way and remove the two bolts (39129-S2) retaining the detent plate to the transmission extension housing. Remove the entire control lever assembly from the vehicle.

Installation

1. Prior to installing the control lever assembly, be sure the transfer case link (7B106) is in the 2H position (pointing upward).

1. Install the two bolts (39129-S2) to retain the control lever assembly (7E069) to the transmission extension housing and tighten to 92-125 Nm (68-92 ft-lb). Refer to the following illustration for bolt hole application.

1. Attach the control rod (7A315) to the control lever assembly (7E069).

1. Tighten the large pivot bolt to 92-125 Nm (68-92 ft-lb).

1. Attach the vent hose (7D494) into the notch in the detent plate so the white mark is flush to the outside surface of the plate.

1. Install the shift handle (7E067) into the control lever assembly (7E069). Tighten the retaining nut to 27-38 Nm (20-28 ft-lb).

1. Check transfer case for proper shifting and operation.
   
   
   
   
   
   
   
   

if you crawl under the vehicle, trace vacuum lines to transfer case they terinate in a group of 3 (vent, vacuum from engine, line to actuator diaphram under battery) . Mark lines (bundle should have a pin to prevent bad replacement, but be safe) pop 3 hose unit , unscrew switch (count the turns to return it to same position). Transfer case side has a ball that should detent fairly easily. If stuck, work it loose or replace the switch. This manual detented switchsimply routes vacuum to diaphram which pulls cable to front axle, or vents it to atmosphere when in 2wd.

You should be able to feel if diaphram is pulling in when in 4wd and is relaxed when in 2wd mode to troubleshoot. Direct vaccum to diaphram line to test. I have used aquarium airline tubing and airstone manifold to provide quick fix when a garage and/or access to parts was not available. You want to be able to direct vent to diaphram for 2wd and engine vacuum to diaphram for 4wd.