4wheel drive problem - Ford Forums - Mustang Forum, Ford Trucks, Ford Focus and Ford Cars

tjbushey · 03-14-2012, 15:40

Hello there, i am having some problems with my 4wheel drive in my 03 ford Ranger 4.0L I posted about month ago about a clunking going in 4wheel and coming out of 4 wheel, well now its clunking all the time in 4wheel and when i was out in the field the other day it completely came out of 4 wheel and sounded like something was spinning / grinding in the front but then couple seconds after hooked back into 4 wheel, i checked the fluid levels in the diff and transfer and there are topped up where they should be.

Not sure what the problem is maybe someone can give me some pointers where i can look, like i said the sound and clunking seems to be coming from the front.

thanks for looking!

**360ci** · 03-31-2012, 18:41

Sounds like the forks in the transfer case are slipping. If you have an electronic transfer case knob on the dash (not a lever on the floor) then the fault knowingly lies with the TCCM, or transfer case control module. The module is located between the front seats under the dash. In some vehicles it's fairly easy to access, others...not so much.

I'd get this checked out before a fork snaps off in the transfer case requiring a rebuild.

If you're due for an axle fluid change, removing the covers, cleaning the magnets and inspecting the gears will rule out any clips/debris that could have caused damage. Then you'll have to seal it up with RTV sealant and refill with fresh fluid. I strongly believe it's the TCCM, or transfer case in general that's causing the noise. Even with the front axle disengaged from putting power to the ground, the front differential still turns with the speed of the front tires/wheels.

tjbushey · 03-31-2012, 20:36

thanks for the reply, i think you might be right but i think the damage is already done, i manual shifted it into 4wheel drive on the transfer case and the problem is still there, i can pick up a transfer case from my buddy with 150,000km on it for 150bucks.

**360ci** · 03-31-2012, 20:59

Price is right, that's for sure. Install isn't too difficult if you have decent mechanics tools.

Sometimes with age, it's best to shut the vehicle off, and then change the transfer case if it's a manual (control lever type). This will limit gear chatter and prolong life.

tjbushey · 03-31-2012, 21:05

I have the electronic kind with the switch, also noticed it wont go into 4w low sometimes and i gotta put it into drive and go forward then keep trying it in 4wlow then eventually goes in

**360ci** · 03-31-2012, 21:09

You can also try slowly reversing while changing modes. The TCCM is fairly low cost used, and expensive new (over 50% more). If you shop around at even RockAuto Auto Parts it'll be beneficial to do before installing a different transfer case. The transfercase may yet be OK, but the TCCM isn't putting enough pressure out to move the fork to the proper location. Installing and using the new transfer case with a bad TCCM may lead to the same fate for that transfer case....