I searched through 12 pages here and couldn't find any answers to my problem so maybe this is a new one. I have a 2006 XLT and I have recently been having problems with the four wheel drive. It will engage perfectly whether stopped or at speed. But, when rolling at speed and I turn the knob to disengage from 4H to 2H it stays in for a little while then comes out with a hard bump. It feels like the bump is in the front end but I am not sure. It seems as though it will disengage perfectly if sitting still but will not when rolling. Also it will occasionally fly out of four wheel, while the knob is still in 4H position, with a loud bump then reingage while rolling. Anyone have an idea what it might be?

Anyone have any Ideas? Any Ford wrenches on here?

i dk man, my 2006 4x4 works good as gold. i wish i could help

__________________

i have the same problem buddie i have a 05 fx4 and ill be driving along in 4h and then it makes a loud sound and bumps and jumps just like yours. i dont no what it is but it cant be good for it. itll pop out of 4x4 then pop back in then out then it its crazy its probly the T-case its right under the driver seat so it sounds like its coming from the frount end but hay im not a macanik so it could be coming from the front end too. if some one could help it would be cool any body have any ideas????

__________________
I have a black 2005 fx4. it has 4.10 rear end gears and a limited slip rear end my trucks compleatly stock.

Thanks for the replies guys. Anyone know where i could find a schematic for the transfer case/front end?

Lyman, I also have 2006 XLT and had the same problem,we put new front axles in and still had the problem, took the truck to a transmission shop. He had the front punkin appart and the transfer case and could not find the problem. I got it back an drove it through this winmter, tried to get what ever the slam was to break something. No luck. So I took the truck back to our transmission guy ( 30 years Experience) and he put a brand new transfer case on and the problem is now fixed. However he took the old transfer case appart and he cannot find out what was wrong with it. So hate be bearer of bad news but you may need a new transfer case. I was talking about this problem on a different thread on here for some time(something about only when it snows, cannot remember the complete title)

Mike

__________________
2006 4 X 4 Extra Cab
4.0 6cyl.
Auto Trany
Everything Stock

Some kind of transfer case issue, mine works fine so i wouldnt know. I would reccomend taking it to a shop and have them diagnose it.

__________________
2004 4.0 4x4 5spd xlt with 175k 4.10 axles, extended cab, cranked t-bars (not maxed), painted black interior, 32x11.5x15 bfg a/t and procomp steel rims
60/40 mod with a shorty console

I did that to an extent pcityranger. I have always done my own vehicle services within reccomended specs, from engine oil, transmission, and gear oils religiously for 25 years. I log them and keep receipts. They went as far as the transfer case and said there was nothing wrong except the oil in the transfer case was burnt. Due to the Wynns Warranty this wasn't going to get paid for anyway so they asked me if I wanted to go further. I asked to see the spec sheet analysis on the oil and they couldn't produce it. It was their opinion that it was burnt. The transfer case oil only had 2500 miles on it. I asked what could be the problem with the oil and they stated cheap oil. I have never used anything but Motorcraft products, in it and on it from filters to windshield wipers and lubricants. I do not believe the oil was bad. Long story short I am yet to tear it down but I am getting ready to and I wasted 485 bucks on labor and time lost taking it in to the shop. This was a Ford Dealership and I am in no way knocking them. I do believe there are some with Managers who should still be selling cars. Unless you take your vehicles to a Ford Dealership for every single service (WITHIN) the reccomended mileage, Do not purchase a wynns warranty. I will eventually find the problem and fix it myself and I will post the results for others with this problem.

This is interesting to me as i have heard its absolutly terrible to engage/disengage 4x4 while in motion? Maybe your gears are slipping from grinding together while at speed in and out of four wheel?

This is a very ignorant response as i use to switch in and out while in motion only to have many people advise me not to. Upon further though i could see why...your in motion just slamming those gears into motion when you stop and let them engage they have like an easy time doing it...idk if that doesnt make a lot of sense haha just my reasoning

----------

When you engage while stopped, you let the gears get ready, then accelerate to speed as normal...when you engage while driving youre forcing those gears to slam right into motion and up to speed with however fast your going i would think thats what i was trying to say before

I bought my truck new and have the owners manual.
"Shifting between 2WD high and 4WD high can be done at a stop or any forward speed."
"Do not perform this operation if the rear wheels are slipping."
Shifting to/from 4WD Low is to be done at a complete stop with the tranny in neutral (automatic) or the clutch depressed (manual).

I dare say that if the transfer case was ever shifted improperly it could be damaged and need to be rebuilt or replaced.
If you are not the original owner, the PO may have screwed it up.

__________________
2006 4.0 5 spd auto 4x4 Super Cab
BF Goodrich Commercial Traction T/A's
Royal Purple Throughout
Alpine Head Unit with some Infinity Noisy Stuff
NW Oregon

I read that the 01+ rangers front drive axle is always spinning and the transfer case engages the front. Also, that the 4x4 will act up if there is a spare on and the circumference will be off, causing issues. My 4x4 is currently acting up and I have the spare on which is of a noticeable smaller diameter. I have have to get the tire mounted on a new rim and i will report back to see if that solves my problem.

Somewhere in the system from the Transfer case to the front axles is either a spring loaded mechanism that keeps the 4 gears and shaft engaged when at speed or it may be centrifugal force. I don't have a schematic to look at to find out. I am looking for a shop manual and maybe there I will find the answer. With the problem I am having the 4 wheel drive engages and disengages just like it is supposed to when sitting in the driveway. It is when you are moving that the problem shows up. It wil fly in and out at certain speeds and will stick in at certain speeds. There has to be a reason it will fly out after it is engaged without asking it too and I am thinking there is a spring mechanism somewhere and that is what started the problem. Probably with the slamming and jerking I have experienced there are some gears that are burred or maybe even broke. I am getting ready to tear her down within the next couple months after I am sure I won't need her and I will fix it. I will most definately post the results so others may benefit from it. I may even get some photos to post. Wish me luck.