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My wife was driving our 2005 EB Expedition a few days ago. As the weather changed into a snow squall, she shifted from 2WD to AWD while going about 40 mph. According to the manual, one can do this as long as one's speed is less than 50 mph.
Almost immediately, we heard a moderate thumping sound. She shifted back to 2WD, slowed down to <30 mph and tried again to shift to AWD. This time, it worked fine and there was no strange sound.
It was a continuing series of thumps that continued as long as the vehicle was in AWD the first time. After putting it back into 2WD, slowing down, and then trying AWD again, there were no additional sounds.
Most likley the t-case was engaged all the way. This happens when the wheels do not match in speed so the case and front end will not engage untill all four wheels match in speed thats all not much to be worried about.
Thanks. I was worried that this might suggest something more problematic with the transmission. I wonder if this is more prone to happen when one is driving up or downhill?
No more prone to happen when you are shifting in a slippery road conditions as the wheels can turn at different speeds. Although it can happen when the going up as the rear tires will turn faster than the front due in a slippery road condition