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Every Ford I have ever had has made that same engagement thump. It never caused problems on the Expedition or the Excursion. I just make sure I'm not actually spinning the wheels when I turn on 4X4.
Mine does it too. I haven't tried it yet with the hubs locked to see if the same thing occurs, but it's definitely louder than the ESOF system in my 2000 F-250.
Originally Posted by EpicCowlick
I just make sure I'm not actually spinning the wheels when I turn on 4X4.
You'll get the check 4x4 system warning if they're spinning. I got stuck in a driveway last weekend, wheels hadn't completely stopped on the ice and threw the switch, warning received and no 4x4. Threw the switch back to 2wd, then back to 4H and it worked fine.
Does anyone know what the actual mechanism is inside the transfer case that spins the front drive shaft up to speed to synchronize with the front hubs or is it just a primitive "bang -whack"?
I would think it's a synchro just like in a manual transmission... but I really don't know.
I can say that there is no noticeable sound from my truck when shifting into 4H. In today's ice, I have shifted in and out a few times. shifts into 4H have mostly been while stopped, but I did a couple at about 5 mph. shifts out have been mostly at speeds under 10mph. no clunks, thuds, or other noises. and it's definitely shifting in and out. I park in a parking garage here at work, and I don't want to wear my brand new tires out, so I shift out of 4H when I get onto the dry pavement inside the garage. smooth every time.