I have a 2002 F-150 4x4 that seems to have front end problems with the 4WD . It hums VERY loud when 4x4 engaged and doesn't want to dis-engage (electronic switch on dash) It can take a couple of miles to shift out of 4WD, or a good pot hole may do the trick. I've even had it stay in 4WD after shutting it off and going into a store.

There are occassional symptoms of concern in 2WD. like a catching sensation in the front end, clunk noises, I've stopped and checked my lug nut on three different occassions because of the feel of the front end.

I test drove one off the dealers lot, everything worked like I expected mine to... The dealer doesn't take the issues seriously and after three visits has never opened anything, just tries to convince me it's OK.

The dealer had a Ford tech look at it, but afterwards admitted that he only told the tech about the noise while driving in 4x4, The tech said it was loud but mainly from being in 4x4 on dry pavement... It's not my fault he came on a day that the streets were clear, the noise is bad on any surface, and for goodness sakes I only use 4x4 when it's needed!

Can anyone give me some information I can take to the dealer to get him to move on it??

 

HI Kurtiskw

I have a 97 4x4 I have found that
backing up a few feet after turning off
the switch will unlock the hubs.
As for your clunking noise I'm
not sure but there are a lot of guys
on this site that know there stuff I'm
sure someone will have your answer.

Good luck, Muff

 

Hu curtiskw and welcome to FTE

How many miles on your truck?
Does it have all 4 original tires on it?

 

The truck currently has about 30,000 miles and original tires. It's been a problem from the begginning. I only use 4x4 in the winter so the subject gets dropped over the summer. But with the end of warranty coming this year I need to get it whipped.

 

I asked about the tires because if they arent all exactly the same size you will get driveline windup.....one end is trying to turn faster than the other so it binds up.
I'm also wondering if the vacuum motor that locks the front axle to the front diff is working properly.....it might not be allowing the axle to disconnect when in 2wd.
Maybe you could take the tech for a drive in a new one off the lot and then in yours to compare.

 

Dave, you're good! They say they switched tires with a new truck from the lot, but I wasn't there to confirm that.. The service manager went with me on the drive in the new one and pretended to not notice a big difference.. In the case of the new truck, it would switch from 4x to 2x in a matter of feet. Mine? blocks.... But he wasn't "sure" that was bad... the noise... "you can hear it in this one too" (yeah, 1/10th the volume). The bad thing is, this is the second dealer I've been too. First one didn't even get the oil changed.

 

The transfer case should switch almost instantly (enough time to lock itself in place and not damage gears). The front axle disconnect should be instantaneously as well. The '97 and up F150s don't take feet or blocks to engage or disengage, unless you have a major problem.

Check you vacuum disconnects at the firewall behind the battery. You should have vacuum and power to engage the solenoids when you flip the switch. If all is well there, then the axle may be suspect.

The transfer case has an electrical motor operating it, and this system has a history of problems. When things like hang ups go on in them, you can feel and hear the clanks and cluncks. It may pop...but that could come from either location...

Keep up the fight, you'll get it fixed with our help.

-Kerry

 

Guys, Thanks! Kerry, I have printed your info and I am taking it to the dealership this week... hope it works!

One thing I missed before, in 4x4 I feel a pretty definate grinding type vibration. that's never good, is it?