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okay, this scared me a bit, but the truck seems to be running fine.
I was in a snowy drive way and couldn't get out, so I hopped out, locked the hubs, and shifted in to 4 hi. Backed up like a foot or two, and tried again, this time there was a huge clunk and then I drove right out of the drive way.
I checked under the truck, no leaks or blown diff, but that scared the hell outta me!
Did I not move the truck enough to allow it to engage in 4? Or did I do some major damage that I just don't know about yet!
Just want some piece of mind of should I let it go, lesson learned...back it up more? Or should I take it in to the shop to prevent more damage later?
I had almost the exact same thing happen on my Ranger. I never did find out the cause, but when it happened I did notice that the transfer case shifter was out of adjustment. It happened the first time I used it after the dealer had done some warranty work and had the tranny and transfer case out. I suspect the mechanic didn't adjust it properly when doing the work. I adjusted it and haven't had it happen again. Not sure if the adjustment fixed it or whether it was just coincidence. I doubt that the clunk caused it to be out of adjustment.
I haven't noticed any problems since the dreaded clunk, which occurred about 6 years ago. Check your adjustment, check for proper operation and make sure there are no new noises. And, if you want additional peace of mind, drain the diff and transfe case fluids and look for chunks of metal.
Even manual hubs require slight rotation before they actually engage - the **** just puts pressure on the lock mechanism, but the splines have to align before the spring can push it in. Yours are probably just a little sticky and waited a few extra turns before locking in & the shock caused the front d'shaft to echo. Ford gears the front diff slightly faster than the rear, which causes binding on high-traction surfaces, and this can also cause a "clunk" when you engage 4WD.
For further POM, pop the **** caps off your hub locks & see if they're rusty or have a lot of grease on them - they shouldn't have either. The grease should ONLY be behind the locks (around the wheel bearings) and inside the spindle.
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