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Old 03-08-2011
Danger06Ranger's Avatar
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T-case popping out of gear?

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...?
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Old 03-27-2011
Join Date: Mar 2011
Location: colville, Washington
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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?
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Old 04-05-2011
Join Date: Nov 2009
Location: Chilliwack, B.C.
Posts: 46
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.
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Old 04-05-2011
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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.
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Old 04-05-2011
Join Date: Mar 2011
Location: colville, Washington
Posts: 7
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?
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