Transfer Case noise
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Junior User
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Transfer Case noise
Hi Everyone.I have a 2003 EX 6.0 4x4 with 320000 miles on it.I am having issues with a noisey transfer case in 4 high and low range. I have just finished doing the front u joints and fwd drive shaft and hub seals and new ford hub locks . It clunks whenever in 4 wheel drive high or low. I would like to overhaul the transfer case. Is this worth it ? Also if it is does any one have a parts breakdown or even a list of parts I should I be looking at. I've had this truck for more than 10 years and have changed so many parts I am not going to quit on it.Thanks ahead of time and any input would be Great.......PS I looked at some other treads for info .
Fleet Mechanic
Joined: Jan 2017
Posts: 1,665
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I'd actually recommend Allstate gear for parts. It's not terribly difficult. I have a writeup on what I did with mine here:
https://www.ford-trucks.com/forums/1...put-shaft.html
You may have to change some bearings, which will likely require a large puller. they can be purchased at HF for not a lot of money, or just build one. I didn't have to, which was nice. For sure don't let it go too long, assuming you've checked fluid level. The chain is the most likely culprit, and when it goes, you'll be buying a new transfer case after you get it towed home. They explode, literally.
https://www.ford-trucks.com/forums/1...put-shaft.html
You may have to change some bearings, which will likely require a large puller. they can be purchased at HF for not a lot of money, or just build one. I didn't have to, which was nice. For sure don't let it go too long, assuming you've checked fluid level. The chain is the most likely culprit, and when it goes, you'll be buying a new transfer case after you get it towed home. They explode, literally.
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Junior User
Joined: May 2011
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2003 EX 4x4 transfer case
Hi There .I just pulled my transfer case and it seems to be in pretty good shape .The chain has about 1" of deflection. Just wondering what the limits are and how do you tell if the gears are worn....Thanks
Fleet Mechanic
Joined: Jan 2017
Posts: 1,665
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As far as the gears, as long as they are in good shape and no missing teeth or bending, I'd say they are probably ok. Also look for bending or curling on the end of the teeth, indicating that the chain has slipped. Not likely, but check it out.
Last edited by Stewart_H; Dec 16, 2019 at 03:02 PM. Reason: added quote after merging threads 2 alleviate confusion
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