SOURCE: Loosing oil on the output
90 percent of the time stop leak does not work. Usually the seal between the transmission and transfercase goes out and forces all the fluid into the transfercase and leaks out the rear seal. Or the tranfercase or transmission breather could be plugged.
SOURCE: ford super duty vibration/shake
The carrier bearing should not move at all. It is mounted in rubber to give a little. But, it should not move freely. If this is the case then something has gone bad. The carrier bearing would cause this vibration as it spins if it is loose.
SOURCE: 1990 ford f150 won't shift into overdrive and has
Sounds like your front hubs are staying engaged, lots of problems with them on Fords, there should be a vacumm solenoid next to the battery, follow the lines down to the wheels and check for leaks. If you have a vacuum guage you can plug the line at 1 wheel and connect the guage to the other when the 4wd switch is placed from 2wd to 4wd h there should be a vacuum signal there i believe its like 12 to 15 hg and when you go back to 2wd its like 6 hg on the guage. If that dont work suspect the solenoid they are prone to water intrusion. if the vacuum signals are correct suspect on of the hubs has a vacuum leak, you need a hand held vacuum pump to test them, connect it to the vacuum port and pull a vacuum it should hold 15 hg for at least a minute, i think the actual bleed down rate is 5 hg per minute per Ford. If the hubs are leaking its a bit of work but not impossible, much cheaper to do yourself than at a shop.
SOURCE: transfer case motor
the brown wire is for the electromagnet inside the transfer case to engage the clutch if the wire is broken right at the case the magnet will need to be replaced
SOURCE: replaced gem module & transfer case motor
Did you check the vacuum solenoid ?
Also, should confirm, is this a ESOF ( electronic shift on the fly ) or MSOF ( manual ).
Could be a few other things, but best to test the easy one ( and mechanical out in the elements )
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