Transfer case rattle
Thread Starter
|
New User
Joined: May 2010
Posts: 7
Likes: 0
Transfer case rattle
I have a 2004 Ford F250 6.0 4 x 4 Super Duty Crew Cab with appox 130,000 miles on it. One of my good friends is a diesel mechanic at one of the Ford dealers here in TN, he is about the only one I let work on my truck. I have had some sort of a rattle for about 5 or 6 years, I though it was coming from a door panel, maybe something loose in there. It's coming from the transfer case, they think it's the chain that has stretched and maybe some gears are worn, I am not having any problems with it, just the noise bothers everyone. They say that Ford makes some of the parts and don't list others and there is no one at the dealership that rebuilds transfer cases. A new transfer case is about $2600.00, don't know if labor is included or not. Anyone had problems with their transfer case? Thanks and sorry for the long message.
FTE Leadership Emeritus
Joined: Sep 2000
Posts: 23,174
Likes: 1,678
From: Stephensville WI
I'd inspect the catalytic converter heat shield first. A common source of a rattle under the truck.
As for problems, no. The NP271/273 family of transfer cases are very heavy duty. GM, Ford and Dodge/Ram all use the TC in their heavier trucks. The only failures I have seen have been from extreme abuse.
As for problems, no. The NP271/273 family of transfer cases are very heavy duty. GM, Ford and Dodge/Ram all use the TC in their heavier trucks. The only failures I have seen have been from extreme abuse.
Thread Starter
|
New User
Joined: May 2010
Posts: 7
Likes: 0
Thank you, I will get them to check that. I am not one to abuse anything I have, things cost way too much to fix, lol. We pull our camper with it which is a 5th wheel 36' and I use the tow/haul mode when doing that. There are some long stretch hills we have to go up and some shorter hills and curves to get to our favorite camp ground, so that's the reason I use the tow/haul mode. I am going to take it to a transmission place someone else recommended when I get it back to let them look at it, hopefully we can figure something out.
Cargo Master
Joined: Dec 2015
Posts: 2,911
Likes: 504
FFS t-cases are stupid simple. The dealer just doesn't want to deal with it. With some snap ring pliers anyone can rebuild a 'case
That said, chain stretch seems unlikely unless maybe it has been run for an extended period on dry pavement.
I'd look elsewhere as suggested and/or be very sure of the diagnosis before bothering to open up the t-case
That said, chain stretch seems unlikely unless maybe it has been run for an extended period on dry pavement.
I'd look elsewhere as suggested and/or be very sure of the diagnosis before bothering to open up the t-case
Cargo Master
Joined: Dec 2015
Posts: 2,911
Likes: 504
Also, in thinking on this more, the chain only moves if you're in 4wd and/or the front hubs are locked.
In 2hi with hubs unlocked if you get this mystery rattle there's no way it's the chain.
Also, I'd kinda expect the noise to change in 2hi with hubs locked vs 4hi with hubs locked and under throttle - being under power in 4hi *should* place a bit more tension on the chain and at least cause the noise to alter in some way.
This is all purely theory (the noise changing part) - I've heard of stretched chains in t-cases but never personally encountered one. The first part about WHEN the chain spins is simply mechanical fact.
In 2hi with hubs unlocked if you get this mystery rattle there's no way it's the chain.
Also, I'd kinda expect the noise to change in 2hi with hubs locked vs 4hi with hubs locked and under throttle - being under power in 4hi *should* place a bit more tension on the chain and at least cause the noise to alter in some way.
This is all purely theory (the noise changing part) - I've heard of stretched chains in t-cases but never personally encountered one. The first part about WHEN the chain spins is simply mechanical fact.
Thread Starter
|
New User
Joined: May 2010
Posts: 7
Likes: 0
I am taking it to a place that works on transfer cases next week, hopefully they can figure out what is wrong. I just don't want someone to open it up and find out there is noting wrong with it, then we are back to square one on trying to find the rattle. Like I said earlier, I am not the kind that abuses anything I have, so this is a mystery to me, I just can't believe that with only has 130,000 miles on it and the chain is stretched. I have had it since 2005 and bought it with only 24,000 miles on it, so I am the only one who has put the miles on it. Thanks for all the suggestions, when I find out what's wrong with it, I will post it on here.
Trending Topics
More Turbo
Joined: Aug 2014
Posts: 546
Likes: 30
From: VA- Shenandoah Valley
Based on what you've shared about how you treat the truck, it is highly unlikely that it is the chain.
FTE Stories
Ford Trucks for Ford Truck Enthusiasts
AEV FXL Super Duty - the Super Duty Raptor Ford Doesn't Make
Brett Foote
Lobo Vs Lobo: Proof the F-150 Lobo Should Be Even Lower!
Michael S. Palmer
Ford's 2001 Explorer Sportsman Concept Looks For a New Home
Verdad Gallardo
10 Best Ford Truck Engines We Miss the Most!
Joe Kucinski
2026 Shelby F-150 Off-Road: Better Than a Raptor R?
Brett Foote
2027 Super Duty Carhartt Package First Look: 12 Things You NEED to Know!
Michael S. Palmer
10 Most Surprising 2026 Ford Truck Features!
Joe Kucinski
Top 10 Ford Trucks Coming to Mecum Indy 2026
Brett Foote
5 Best / 5 Worst Ford Truck Wheels of All Time
Joe Kucinski
Thread Starter
|
New User
Joined: May 2010
Posts: 7
Likes: 0
Stuart, I looked at my converter and it has like an aluminum wrap around it so I don't think that would make it rattle. I shook the exhaust system to see if something was wrong there, and there is a lot of play and slop in the rubber hangers, just wondering if that could be the noise. A few years ago the rear tail pipe hanger had broken and was bouncing up and down making a clunking noise, it was fixed and been good every since. I am still going to take it and have a transmission shop Monday and have them listen to it and see what the can figure out where it's coming from. Thanks, I will let you know what they say.
Thread
Thread Starter
Forum
Replies
Last Post
1979F350/460
1973 - 1979 F-100 & Larger F-Series Trucks
8
Apr 18, 2012 07:10 AM