Drove home, stopped at mailbox in park, then was extremely difficult to get in drive, parked at house.
Took cable loose at lever on trans, lever would not move freely through gears, assumed after reading much forums and watching utubes that it was the"range sensor", the part just inside the case. Removed and replaced "range sensor" with new unit.
I haven't replaced the pan yet, gears cannot still be changed with lever on trans.
Unit is a reman Jasper unit replaced approximately 25k miles ago.
What is possible causes of not being able to move trans lever with cable disconnected?

 

When you can't shift out of park position the very first thing to check is the brake pedal switch before you remove the cable.
You said you removed the shift lever cable and you can't shift it by hand at the range sensor? How about you remove the range sensor and do it by hand in case it wasn't line up at N position?
And have you checked your dipstick yet?

 

The brake switch is functional. The fluid level was fine before I removed the pan, now it is empty due to pan being still off. When I removed the original range sensor, the only things I saw to try to move was a plunger type device actuated by the pin on the quadrant of the sensor. The plunger would not move in and out with the sensor removed.

 

What is the engine size, 5.4L or 6.4L or 6.8L, let me try to get you some diagrams and pinpoint test.

 

Could there be a problem with the lever in the steering column ?

With the cable disconnected from the trans, the trans and everything in it is out of the picture.
The problem is what moves the cable or the cable itself.

Can you look a little deeper into that part ?











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It's a 6.8, but I think that's not too relevant, I don't know.
Should I be able to move through all gears via the lever on the side of the transmission case, using my hand, laying under the truck, with the shift cable disconnected?

 

If you cannot move the shift lever with the cable disconnected, looking inside the trans at this time is a wild goose chase.

Best to take things one at a time.

Find out why you cannot move the lever that moves the cable. Once we get that fixed , we can move to the trans connect the cable and see if there is a problem there..

 

I don't think I'm making myself clear. But thank you

 

I believe I now what you are asking.

You should be able to see what the lever you are asking about, moves. It moves what we call a spool valve .If something is causing that mechanism to bind or jam, the only thing I would do is lower the valve body and find out if the spool valve is jammed with something or the linkage is causing the problem..

I don't know if you want to get involved with this problem. Is there any kind of warranty with that trans ?

That lever on the shaft inside, should have a toothed portion that a flat spring loaded roller rides in the different teeth positions.I believe once you see what moves you might be able to figure out what is not working or working right.
Thanks for your patience !

What Heiko suggested is also something you might want to review and that is if the marks on the sw assy were lined up for neutral and the trans was in neutral when you installed the replacement sw assy.