Hey all. I took a scan through the posts and found stuff that sounded similar to my problem, but not exactly the same. I have a 03' 4x4 extended cab 4.0L w/ 5 speed auto and 40k miles. A couple of nights ago we had a snow storm. So as I'm driving home from work, going 35 to 45 mph, I flip the switch and put it in 4hi. I hadnt gone 5 miles down the road and I felt the truck lurch and heard a clunk/pop noise coming from under the truck. I didnt know what to thing so I kept driving and about another 3 or 4 miles down the road it did it again. At this point I take it out of 4wd and try to creep along in 2wd. The roads are a little ice and snow covered so i figure "screw it" and I put it back into 4wd. Well this clunking happens again and again but now its taking about 10 or 12 miles between clunks. I noticed it feels like its going into neutral when it happens but that might just be my imagination. I've only driven it once since then and only in 2wd. Everything seems fine in 2wd but im not sure i want to test the waters and put it in 4wd to see if it's going to do it again. I bought the truck brand new in Feb. of 03' and this is the first time I have had any problems with it. I have only used the 4wd a hand full of times, but this is the first and only time I have heard any noises. I have spoken to a few people and some say the switch in the dash might be bad and its popping in and out of 4hi and 4lo or possibly 2wd and 4hi. Anybody got any other suggestions?

 

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How many miles? Provided you were not on dry pavement, and if there's under 36K on the clock, I'd take it in for warranty service.

 

Its got 40,000 miles on it. I bought the extended warranty so I'm good up to 100,000. I just got off the phone with a mechanic at a local Ford dealership and he seems to think it might be rust breaking the seal and the hubs not getting enough vacuum causing the hubs to lock and unlock. I wouldnt think there would be rust on a truck this new but what do i know??????

 

Correct me if I'm wrong 4x4 guys, but an 03 has hubs that are always locked, the PVH system went away in the middle of 2000.

 

Ya, 00's on up don't even really have hubs....its just locked all the time like Ken00 said. I dunno about you, but If a Ford Mechanic told me an excuse like that, I might be looking for a different dealership to go to. Or at least a different mechanic.

As for the problem....you might want to get under the truck and remve the electric shift motor from the transfer case and clean it up. It might have gotten some dirt or mud or whatever around it, and i've read on other threads it can cause t-case shift problems. Not sure if that would be your problem, but its an easy place to start.

Also.....the day that it clunked and lurched in 4wd high...are you sure that the truck actually engaged 4wd high in the first place? Like were you at an icy intersection and accelerated hard enoguh you could tell for sure the 4wd was working in the first place? Just wondering....

 

If it is under warranty then take it back and if they don't fix it, then take it back. If you are still dissatisfied then call the Ford Motor Co, and really complain. They will stand behind it, they don't need the bad PR. A new truck under warranty, I have never had them fail to repair any problem, but then I have never had a major one either.