2007 4L automatic
my transmission was just recently replaced along with the transfer case...
2wd is fine but when I switch to 4H or 4L when i'm driving (slow or fast) it makes a horrible noise and jolt every 5-15 seconds (the speed does not change the timing of it happening).
If it is in 4H and i ignore it and put a big amount of load on it the front tires will stop spinning and ill have to completely stop for it to go back in.

yes i come to a complete stop and put it in neutral when i shift in or out.

I'm just trying to figure out if its a easy fix or if i should just get a new one

 

You can shift to 4h and back to 2wd when moving, under 45MPH is highest speed recommended, and NOT on dry pavement, its a 4WD NOT an AWD
To shift to 4L and back out, you MUST BE STOPPED and shifter in Neutral, period

You can not use 4h on dry pavement as transfer case can bind up, dirt(mud), gravel, snow, and ice are OK
4WD means transfer case is connecting front and rear drive shafts directly together so both must spin at the same speed or there will be binding, to start, ALL 4 wheels/tires need to be the same diameter and same air pressure, otherwise drive shafts won't spin at same RPM
Check that all 4 tires are the same size

The Propeller joint on the front driveshaft from 1998-2011 Rangers did wear out, but "clicking" noise in 2WD as well as noise in 4WD would be the indicator

Anyway, try it out on dirt or gravel road FIRST to see if issue goes away, its possible the new transfer case has an issue, "new" means NEVER EVER TESTED, not "it works"

 

I only use 4 when I can’t go anywhere in 2. When I said about it popping out of 4 that was when I was going up a snowy hill on a field. Once it hit about 25-35 km/h it would pop out... the tires were spinning at that speed but the truck was only moving around 10-15km/h. Yes the tires are the same size and would the air pressure and wear of the tires really matter if they are all spinning on a snowy field?

(I would have responded quicker but my password got messed up and I could not get back in)

 

If you were in 4low then yes, it might pop out, thats too fast

But 4high should have stayed in

Once all wheels are spinning you are pretty much done
Point if 4WD is that if one wheel spins a bit the others keep vehicle moving until the spinning wheel has traction again
You can get speed up on the flat part of the road to start going up hill but slow and steady, on the uphill part because once you lose traction thats as far as you can go

 

Yes I know all of that stuff.. I only use low when I’m pulling someone out of the ditch.. I am running it how I am supposed to and I am trying to figure out why it pops out because I can’t find anything on the internet.

I should be able to have my front tires on clear gravel and the rears spinning on ice and stop then put it in 4H and pull myself ahead not listen to it grunt and kick out

 

Sounds like your front differential might be bad.

 

There is an adjustment on transfer case shift motor to line up 2H, 4H, and 4L

The shift motor has 5 contacts that "tell" the controller the position of transfer case shift rod, seen here: https://www.therangerstation.com/tec...e-shift-motor/

The contact plate is adjustable, meaning you can rotate the contact plate a bit so controller will put shift rod a little left or right of where it is now

To test I would put the shift motor in 4high then pull it off and see where shift rod is pointed, it it pointed right at 4h or a little left or right of it
Do the same to 4l, and 2h
See of rotating contact plate will shift all 3 to the right or left as needed

If thats not the issue then could be a detent that holds transfer case shifter in 4h is worn out

You can remove shift motor and use tied off vise grips to hold shift rod in 4h and then go for a drive to see if it still pops out, that would indicate internal issue in transfer case

 

Ok if the differential is the problem what would I do to know.
and I will try playing around with the transfer case motor to see if that changes anything

 

Now I am starting to think it is the shift motor because I was thinking about it some more and after I loose 4wd I stop for it to go back in and I can hear the motor when it goes back in so I think I will definitely try looking at it