What kind of gas MPG can I expect? I am thinking of buying one. Does the 4wd unit have a manual transfer case? I also keep hearing rust is an issue?

 

Well, my '04 has the 4.0 SOHC 6-cylinder, manual transmission, 4WD, and a 4.10:1 limited slip rear axle.

Lately, I've been averaging around 20mpg - that's mixed city/hwy - mostly hwy @ around 55-60 mph.

The 4WD is electric - there's a **** on the dash to turn to get it into 4hi or 4lo. I like the idea of having a manual lever, like my '77 does - but, so far this electric setup hasn't failed me yet.

I've checked mine over for rust - apparently, the spring shackles & hangers are prone to rusting out. I think some of that depends on where you live, though. It's pretty dry around here and the hangers still look pretty good on my truck...

 

^ Nailed it. I've got an 01. Watch out for timing chain tensioners on the '01-02.5' 4.0L SOHC's

 

Same luck here with my '05' 4.0L manual ext cab 4x4 with the 4.10 gears. Mostly interstate and could get almost 22 mpg in good weather. Some did come with the manual xfer case but those were the high end FX4 Level 2's I believe.
Dave

 

smalltrucker: The manual tc's came with the manual tranny. Autos had the electric.