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I have a 2004 F150 supercab sidestep with the 5.4. When I engage the 4x4 and accellerate 2-12 mph I get a shake that shakes the whole truck.
The dealership now thinks it's possibly something inside my transfer case that is loose (they have torn apart the front end multiple time and said it is all good). Afterwards I found 3 bad ball joints and a loose rear shock. I fixed those and prayed. Needless to say, engage 4x4 hi, accellerate and the truck shakes. I don't get any shaking in 2wd.
What could case this? Is it possible that it is the transfer case? Is there some checks I can do to try and find the problem without yanking the transfer case apart? 4x4 worked just fine last winter and right away this winter I have had the shaking issue.
According to the dealership, the front driveshaft and differential is fine. They replaced the CV axles (because they were bad) and told me they can find nothing else wrong with the front end. This was after they said they tore the front end apart 2-3 times trying to find the issue. Now they want to drop the transfer case and tear it apart to see if something is loose inside.
I found 3 bad ball joints after the dealership worked on it and replaced those. It reduced the shaking but didn't eliminate it. I think the ball joints were just allowing the shake to increase.
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