Attempting to replace the transfer case motor on my 94 Ranger 4x4 4.0L. The auto locking hubs were replaced with manual a few years ago and worked fine until the TC motor went. Did not think much of it - Just get another motor and replace the bad one. I get that the little stud on the TC has to be aligned properly to fit into the TC motor. On mine it is triangular shaped - like an arrow.

If both pieces are aligned properly, will they just snap in place or is there a trick to this? I'm fairly certain they are aligned properly or very close, but I cannot get them coupled. If I hit the 4x4 button with the new motor connected but not bolted in place and then manually point the TC stud to 4x4 do you think that will help?

I've even tried to put the old one back on so I could continue to drive in 2H, but can't even get that one to couple.

Thanks for any advice.

Okay, so...nevermind.

I finished the install and all seems to be right (still need to go for a ride to be sure everything engages and disengages the way it is supposed to

Here's the deal -- to no one's surprise I am sure -- IF IF IF everything is aligned perfectly the two pieces will couple with just a little effort. Getting them to align is another story. In 2H, mine was a fraction of an inch off, or millimeters if you prefer. There's not enough room to twist the motor up or down to get them to align in 2H. Trying to get the TC stud to stick somewhere in between wasn't working because it wants to snap into it's proper place - 2H, 4x4 or Low. My solution was wiring up the motor and placing it in 4x4. Then I got lucky and found a niche just off of 4x4 that gave me just enough room to twist the motor and snap it onto the stud.

Geez what a pain. Hope this helps someone along the way. Sorry for the long post.

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1994 Ranger Splash XLT 4x4 SuperCab.
Manual locking hubs (out of necessity)
4.0L Automatic OD. 247K
All stock equipment - for now.