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I just cleaned the engagement motor, for the 4x4 it works great, but i just used my 4x4 yesterday and today due to the snow, and it rumbles or roars (hard to explain th exact sound), but i was wondering if they is normal, or is something bad, Hubs?? Fluid in the T-case?
My first checks would be fluid levels in the front differential and the transfer case and the u-joints on the front driveshaft and axles.
A little bit of additional noise when the front end is engaged is normal, but it shouldn't be excessive. Is there an accompanying vibration? Under what circumstances does it rumble? t-case and hubs locked? t-case in 2WD with hubs locked? t-case in 4WD with hubs unlocked (if you have manual hubs)?
no vibration at all, just sometimes or often it rumbles, then other times it will be fine, it does not do it in 2wd, or yesterday after i turned the 4x4 off and was still driving did not back up the ten feet to disengage the hubs, no rumble, but it does it almost all the time while its in 4x4
check the front diff fluid and the transfer case fludio my x did the same thing and the fluid was low i filled it up and it made less noise but i drove it in the snow storm last weekend and it got less and less until normal when was the last time you used the 4x4 ford recomends driving it for over a mile once a month