2002 FX4 transfer case problems - Ranger-Forums - The Ultimate Ford Ranger Resource


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Old 12-29-2013
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2002 FX4 transfer case problems

Hi guys

I have a 02 fx4 offroad ranger. Since a few days ago, every time i put it into 2wd and i drive it for a few metres or more it clunks really really bad. It sounds horrible and its even worse when I turn. It sounds like a horrible clunk/thump.

When i put it in 4wd high, I have no problems. It drives just fine. Same with 4low. So i put my transfer case in 2wd and hoisted it up and when i turned the back wheels the front one also spun.

I'm not sure what to do..since the clunk is so bad I've just been driving around in 4wd high.

Any feedback would be greatly appreciated. Thank you very much.
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Old 12-29-2013
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Seems like it's partially disenaging. Have you tried unlocking the transfer case manually?
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Old 12-29-2013
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How would i go about unlocking the T case? im not sure
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Old 12-29-2013
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I've never done it myself but I think you can do it by taking out the shift motor from the back of the transfer case
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Old 12-29-2013
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I don't have an electric shift motor. i have a lever for the transfer case right beside my gear shifter.
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Old 12-30-2013
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You can disconnect the linkage to the transfer case. Then move the shift lever on the transfer case all the way to the 2WD position. If that eliminates the problem, your shifter needs to be adjusted. You can also check to see of anything has gotten in the shift mechanism that is keeping it from shifting all the way.
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Old 12-30-2013
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Quote:
Originally Posted by 2ranger View Post
I don't have an electric shift motor. i have a lever for the transfer case right beside my gear shifter.
Just rub it in my face then lol. Lucky
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Old 01-03-2014
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Ok thank you IN2 FX4 i'll try that and see how it goes. how do i do that second part of checking if anything is in the shift mechanism?
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Old 01-03-2014
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You can look up into the shifter mechanism from below to start with. If that shows OK, you can pull the boot on top but as I recall, there is not much to see there. Almost everything is accessible from below.

There is also an adjustment you can do if there is no clearance between the shift lever and the cam plate in the front in 2wd-hi and in the rear in 4wd-low. I have added the adjustment instructions below. Ignore the statement about raising the boot to expose the top surface of the cam plate. You will have to remove a lot more than the boot to expose the top of the cam plate. As I said before, everything should be accessible from below.

If you do lift the boot, don't use the fake Allen head screws. They are for show. You can just lift the boot out of the chrome plastic frame.
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Old 01-03-2014
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Ok. Thank you so much. i'll try that.
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