Just bought a 99 F250 SD, V10 4X4 and had the transfer case go bad at 1490 miles.
I was doing 70mph. with no load and heard a quick, fast grinding noise. The truck then acted like it was in neutral--no forward or reverse. Truck was towed by 1-(800) FORD ( roadside assistance ) to nearest dealer. They stated this is a very common problem that affects approx. 10% of all Super Dutys on the road however they always seem to be PowerStroke diesels that tow heavy trailers. The dealership was going to put a new transfer case in just like they had in the past. A Ford Engineer happened to be on-site and said Ford was aware of the problem and expects a recall sometime in June. In the meantime he provided a part number for the fix which is a new in-put shaft coupling ( back half of transfer case ). Apparently some units are way out of tolerance and the engine torque wears out the shift fork leaving the unit in neutral. The part was back ordered and I needed to get home so they installed a new transfer case with 3.5 quarts of 100% synthetic fluid vice 2.5 quarts of MercronATF. The engineer said that I might go 100 miles before it fails again or 10,000 miles but it still needs this new in-put shaft coupling. I made the 1400 mile trip home without a problem and will be at the local dealer on Monday to get the part ordered.

 

 

You met a ford engineer and you didn't pop him one right in the nose!

 

And you resurrected a 10-year-old thread why?

 

This has got to be a FTE record.

 

Lmfao!!!!!!!!