Ok... I know this is gonna need some more diagnosing, but figured I'd let y'all get your diagnostic juices flowing...

The F-350 4x4 CC DRW that was just donated to my property had the transfer case replaced the week before it was donated. (Previous owner said it had been making some noises and wanted to replace it for us so we didn't have to worry about anything). I've run the truck at most 500 miles since the transfer case was put on, and have run the 4x4 a few times since we got it. Every time I ran it (until last night) it didn't really feel like it was coming on. My back tires still spun a little bit and I could make really tight turns without the truck bucking at all. Last night I turned it on going up a fairly steep gravel hill, pulling a 5000# trailer, and I could tell that time that it had actually come on... But...

As soon as I put the 4x4 on, there was a fairly loud clunking/vibration noise that seemed to be in sync with the wheels turning (I was moving pretty slowly). Any thoughts on what might cause that? And yes, I know that "loud clunking/vibration noise" isn't very descriptive. But it was midnight last night, I didn't feel like continuing to do more diagnosis, and so figured we'd start from here... what things do you all want me to check for?

 

Sounds like the front wheel hubs might need some regreasing and new set of o-rings. I'm away from my home computer but there is a procedure to regrease and replace new o-rings on the front wheel hubs. As soon as I get home, I'll send u the link.

Another possibility might be ur transfer case itself. Now since it was replaced, here's a question. Was the transfer case fluid filled up to required level? U might have to drain and refill the transfer case. Maybe it was underfilled. Tat could be a prob too.

 

Yeah, not sure... I'm tempted to go try manually locking the hubs, but the previous owner happens to be here right now and offered to drive it back to the mechanic who put the new case in and make sure it gets fixed right and then bring it back to me... 8 hours driving round trip, and I won't have to worry about it. I can do without it for a few days, so I'm taking him up on his offer...

 

Ok. Sounds like a plan.