Notices
6.0L Power Stroke Diesel 2003 - 2007 F250, F350 pickup and F350+ Cab Chassis, 2003 - 2005 Excursion and 2003 - 2009 van

Transfer case carnage

Thread Tools
 
Search this Thread
 
Old Dec 27, 2021 | 12:09 PM
  #1  
ms1780's Avatar
ms1780
Thread Starter
|
Mountain Pass
Joined: Nov 2006
Posts: 182
Likes: 1
Transfer case carnage

My transfer case and front drive shaft decided to remove themselves from the truck at 75 mph last night. It made for quite the racket a few sketchy minutes. Has anyone ever had this happen? There was no warning signs before hand. For about two seconds it felt like I was driving on the rumble strips then it flew apart and I'm assuming the shaft was beating the bottom of the cab until it broke loose.


 
Reply
Old Dec 27, 2021 | 12:20 PM
  #2  
Chainfire's Avatar
Chainfire
Cross-Country
Joined: Sep 2019
Posts: 90
Likes: 21
I've had them fail but never disintegrate like yours.
 
Reply
Old Dec 27, 2021 | 02:49 PM
  #3  
Yahiko's Avatar
Yahiko
Fleet Owner
10 Year Member
Liked
Loved
Community Favorite
Joined: Apr 2012
Posts: 27,307
Likes: 549
From: Spanaway
I had one come apart after I whacked something very hard with the front end.
How ever it was at low speed.

 
Reply
Old Dec 27, 2021 | 03:11 PM
  #4  
joe blow's Avatar
joe blow
Logistics Pro
20 Year Member
Liked
Loved
Community Favorite
Joined: May 2004
Posts: 3,616
Likes: 882
Holy crap! Sorry that happened.

What in the world happened?
 
Reply
Old Dec 27, 2021 | 03:52 PM
  #5  
Yahiko's Avatar
Yahiko
Fleet Owner
10 Year Member
Liked
Loved
Community Favorite
Joined: Apr 2012
Posts: 27,307
Likes: 549
From: Spanaway
Mine was back in July 2018.
I tangled with a center barricade.

ms1780 may of been a bearing going out. If he can find the bearing
and clutch assembly I would like to see the photos with closeups.

What type of oil was used in the transfer case? I do hope that
there was no transmission damage. In mine I got away with no
damage to the transmission.
 
Reply
Old Dec 27, 2021 | 06:59 PM
  #6  
ms1780's Avatar
ms1780
Thread Starter
|
Mountain Pass
Joined: Nov 2006
Posts: 182
Likes: 1
My theory is the front u joint failed which then quickly beat the t case to pieces but that's just a theory. I had my 14 year old with me so it was a good lesson for him on what to do when the **** hits the fan at high speeds.
 
Reply
Old Dec 27, 2021 | 10:30 PM
  #7  
six_eaux's Avatar
six_eaux
Cross-Country
Joined: Aug 2021
Posts: 96
Likes: 55
A failed U-joint would be my guess too. Glad to hear that you and your boy weren't hurt.
 
Reply
Old Dec 27, 2021 | 10:33 PM
  #8  
TooManyToys.'s Avatar
TooManyToys.
Hotshot
Photogenic
Photoriffic
Shutterbug
Joined: Dec 2014
Posts: 17,833
Likes: 3,121
From: Jersey Shore
Were you in 4 wheel drive at 75? If not in 4x4, the shafts should not be turning.
 
Reply
FTE Stories

Ford Trucks for Ford Truck Enthusiasts

story-0

This Hennessey Takes the Expedition Tremor's Off-Roading Capability to the Next Level

 Verdad Gallardo
story-1

Top 10 Fords at 2026 Carlisle Ford Nationals

 Joe Kucinski
story-2

3 Best / 3 Worst Parts of Modern Ford Ownership

 Brett Foote
story-3

10 Amazing Upgrades That Solve Common Ford Truck Owner Headaches

 Pouria Savadkouei
story-4

Every 2026 Ford Engine Explained

 Brett Foote
story-5

10 Ugly Ford Trucks That We Still Kinda Love

 Joe Kucinski
story-6

10 Things Every Truck Owner NEEDS (2026 Edition)

 Michael S. Palmer
story-7

Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath

 Verdad Gallardo
story-8

Top 10 Most Expensive Ford Trucks Ever Sold on Bring a Trailer

 Joe Kucinski
story-9

2027 Ford Super Duty Buyer's Guide (Every Model, Engine, & Package)

 Brett Foote
Old Dec 28, 2021 | 09:47 AM
  #9  
craftsmangary's Avatar
craftsmangary
More Turbo
15 Year Member
Liked
Loved
Community Favorite
Joined: Jun 2009
Posts: 580
Likes: 58
From: Michigan
Usually that is caused by having the hubs locked in and a bad universal joint in the double Carden, it'll vibrate and the vibration has the whip effect down the line. I see a few of these a year.
 
Reply
Old Dec 28, 2021 | 07:16 PM
  #10  
ms1780's Avatar
ms1780
Thread Starter
|
Mountain Pass
Joined: Nov 2006
Posts: 182
Likes: 1
I was not in 4 wd. I believe the hubs were in auto lock mode but I'm not 100 percent on that. It's going to be about 2k to fix it. That's about $400 in labor and the rest in parts. The shrapnel took out a rear tire too.
 
Reply
Old Dec 29, 2021 | 09:09 AM
  #11  
runthatjunk's Avatar
runthatjunk
More Turbo
15 Year Member
Liked
Loved
Community Favorite
Joined: Nov 2009
Posts: 527
Likes: 278
From: Kansas
I've never messed with the 4WD vehicles, is this why guys go to manual hubs? Does the 4wd system not actually have a way to sense when the auto hubs are locked/unlocked?
 
Reply
Old Dec 29, 2021 | 10:34 AM
  #12  
TooManyToys.'s Avatar
TooManyToys.
Hotshot
Photogenic
Photoriffic
Shutterbug
Joined: Dec 2014
Posts: 17,833
Likes: 3,121
From: Jersey Shore
Probably one or both of the hub stuck engaged then.

There is no sensing for if the hubs are engaged. Several people have discovered the hub were not engaged, either by having someone look at the driveshaft when slowly forwarding, grasping the driveshaft and seeing if it's locked or engaged, or for me, vibration at higher speeds.
 
Reply
Old Dec 30, 2021 | 07:54 AM
  #13  
Baylinerchuck's Avatar
Baylinerchuck
Cargo Master
Photoriffic
Community Builder
Liked
Loved
Joined: Dec 2021
Posts: 2,395
Likes: 999
From: Chambersburg, PA
Wouldn’t both hubs need to be locked or stuck to turn the drive shaft? Just curious. I know at times I’ve had to back up a few feet to release mine. Like you said, I can definitely feel when I’m pushing my front diff.
 
Reply
Old Dec 30, 2021 | 10:00 AM
  #14  
87crewdually's Avatar
87crewdually
Lead Driver
15 Year Member
Liked
Loved
Community Favorite
Joined: Dec 2006
Posts: 6,496
Likes: 94
From: So. Jersey
I'm guessing you didn't do a thread search but here you go. I've seen a few of these grenade. I posted Pics in the other thread. https://www.ford-trucks.com/forums/1...l#post14770239
 
Reply
Old Dec 30, 2021 | 10:09 AM
  #15  
TooManyToys.'s Avatar
TooManyToys.
Hotshot
Photogenic
Photoriffic
Shutterbug
Joined: Dec 2014
Posts: 17,833
Likes: 3,121
From: Jersey Shore
Originally Posted by Baylinerchuck
Wouldn’t both hubs need to be locked or stuck to turn the drive shaft? Just curious. I know at times I’ve had to back up a few feet to release mine. Like you said, I can definitely feel when I’m pushing my front diff.
Pete has this history covered with the thread.
 
Reply



All times are GMT -5. The time now is 06:33 AM.

story-0
This Hennessey Takes the Expedition Tremor's Off-Roading Capability to the Next Level

Slideshow: The VelociRaptor Expedition gains a lift, upgraded suspension, Brembo brakes, and trail-ready equipment while retaining the stock 440-horsepower EcoBoost V6.

By Verdad Gallardo | 2026-06-12 11:01:55


VIEW MORE
story-1
Top 10 Fords at 2026 Carlisle Ford Nationals

Slideshow: Top 10 Fords at 2026 Ford Nationals

By Joe Kucinski | 2026-06-09 11:10:08


VIEW MORE
story-2
3 Best / 3 Worst Parts of Modern Ford Ownership

Based on years of owning multiple modern Ford products.

By Brett Foote | 2026-06-09 10:53:36


VIEW MORE
story-3
10 Amazing Upgrades That Solve Common Ford Truck Owner Headaches

SPONSORED: From muddy boots to rain-soaked cargo, these upgrades address some of the most common frustrations Ford truck owners face every day.

By Pouria Savadkouei | 2026-06-08 18:50:34


VIEW MORE
story-4
Every 2026 Ford Engine Explained

Here's everything you need to know about every Ford engine available for the 2026 model year.

By Brett Foote | 2026-06-05 12:58:01


VIEW MORE
story-5
10 Ugly Ford Trucks That We Still Kinda Love

Slideshow: 10 ugly Ford trucks that we still kinda love.

By Joe Kucinski | 2026-06-03 09:51:16


VIEW MORE
story-6
10 Things Every Truck Owner NEEDS (2026 Edition)

Slideshow: the best gifts for dads & grads

By Michael S. Palmer | 2026-06-03 15:43:58


VIEW MORE
story-7
Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath

Slideshow: Called the Fortress, the 850-horsepower pickup combines Raptor underpinnings with military-inspired features, survival equipment, and a starting price of $285,000.

By Verdad Gallardo | 2026-06-03 11:38:36


VIEW MORE
story-8
Top 10 Most Expensive Ford Trucks Ever Sold on Bring a Trailer

Slideshow: 10 most expensive Ford trucks ever sold on Bring a Trailer.

By Joe Kucinski | 2026-05-27 16:24:34


VIEW MORE
story-9
2027 Ford Super Duty Buyer's Guide (Every Model, Engine, & Package)

Here's everything that has changed for the latest model year.

By Brett Foote | 2026-05-27 16:17:28


VIEW MORE