When I switch to 4HI in mud/snow, it feels like the t-case is popping out of 4wd. It will pull strong, but then it bangs and the rear end gets squirrely. It seems fine in 2WD. I just changed the fluid at 35k or 40k, and used the recommended fluid, and it didn't do it before. Any ideas...?

 

Hey, I have the same problem with my 05 FX4. Clunks hard and pops into 2wd from 4 Hi, but the dash light is still lit up. Did you figure out what was wrong with yours?
Thanks

 

If its a manual t-case check the linkage, mine would pop out of 4hi by hitting bumps on fsr's. One of the bolt holes went oval lol. Too much play.

 

i had the same issues. ill go like 2mph and switch in a it goes BANG!! then i keep driving. ford gave me an invoice saying normal condition. so if it goes BANG!! again and something breaks ill just wave that paper in there face.

 

Yeah I cant figure it out... replaced t-case, 2 shift motors, checked and changed diff fluids. Its an electric shift 4x4, turn dial switch. Definitely pops out of 4wd into 2wd... 4x4 light stays on. Clunks hard every few seconds, but not consistant with wheel speed? Hasnt thrown any DTC's from the tcase. Could the CV's be ****ed and binding then kicking out the tcase?
I thought I read somewhere inner tie rod ends were a problem for 2004's? could this be a possibly for my 05?

 

Hey guys, I’m sure by now you figured out the problem with your T-case but if not look up “07 4.0L keeps popping out of 4x4” and you are what I ended up doing to fix the problem. Hope this helps

 

I have a 1994 ford ranger 4.0 with a 5 speed and a manual transfer case so it will go into 4lo but it pops out of 4high either in neutral or 2wd I was wondering what could be the issue