2002 4x4 transfer case issues
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From: ft rich
2002 4x4 transfer case issues
Alright, so ive pretty much serviced everything from the front bumper to the end of the transmission. i went as far as pulling the front diff apart to see if those *****ty little pieces of plastic were still attached to the shift fork. Now, for the problem. My truck would "clunk" very hard when the transfer case was under load (accelerating, turning, etc.) the 4x4 would go out and since I'm in alaska, id fish-tail everywhere. it would eventually go back into 4x4. about an hour ago i changed the oil to see if i could find metal or some sort of clue. the oil was brown and didn't smell burnt. i changed the fluid out and i haven't had a clunk since, even after i was drifting around a parking lot. well i had my truck on the lift, i put it in 4x4 and 2x4 and it was making a faint clunk but at a faster rate well the truck was idling in 4x4. after i changed the oil it still was making a rapid clicking and clunking sound, and the front wheels seemed like they were losing power. i say this because they seemed to spin at different speeds compared to the rear wheels. i also pulled the electric shift motor. it turned when i changed from 4x4 to 2x4. I have a borg warner 4406 i believe. its the electric shift on the fly crap. im completely stumped. any speculation is appreciated.
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Joined: Sep 2006
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I don't know if you have a problem or not except for the statement about going out of 4X4 and back in again.
In 4x4 the front cannot turn at any speed different than the rear because the drive line is gear driven both directions.
When you have it on a lift is the front wheels hanging down such that the CV shafts are at severe angles while your running it in 4wd? If so that's not a good thing to do.
Otherwise you need to give positive discription of a problem other than what you know to be proper 4wd operation.
What happens in 4L?
I can tell you how it all works but until you get a firm handle on what's happening I will leave it to later, if needed.
Good luck.
In 4x4 the front cannot turn at any speed different than the rear because the drive line is gear driven both directions.
When you have it on a lift is the front wheels hanging down such that the CV shafts are at severe angles while your running it in 4wd? If so that's not a good thing to do.
Otherwise you need to give positive discription of a problem other than what you know to be proper 4wd operation.
What happens in 4L?
I can tell you how it all works but until you get a firm handle on what's happening I will leave it to later, if needed.
Good luck.
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From: ft rich
The cv joints aren't at an extreme angle. It's hard to describe. I said the front wheels spin at a different speed. I thinks it's because the transfer case is literally disengaging. It's a million times worse on pavement. The truck feels like it hit a rock then goes into 2 wheel. I say this because after the clunk I start fish tailing... Then when I get back to a steady speed or a complete stop its in 4x4. I know this because I can feel it when I make a sharp turn.
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