The truck is a 04 F240 auto, man hubs. When the transfer case is engaged,
there is a howl or gear noise. I have rarely engaged the 4wd since last winter. Seams like its louder that I remember.

Should I be able to hear the case? Of course the truck is out of warranty now.

Thanks

 

There is always some noise (howl, hum, slight grind, etc.) when you put it in 4WD and start cruising. If I were you, just for safety's sake, I would check the fluid level in the transfer case. It's very easy. There are 2 plugs at the very rear of the case, facing the rear of the truck. If I remember correctly, they have a hex pattern on them and you remove them with a hex bit. With the truck cool, remove the top one. The fluid should just start to drip out, or be no more than 1/4" down from the hole. If it doesn't drip, stick your pinky in there. If it's low, it usually takes plain old Mercon/Dexron III ATF. You said you had manual hubs, but what do you do to engage the transfer case---manual lever on the floor, or switch on the dash ??? If it's the switch on the dash (ESOF), then it's definitely the ATF. If it's a manual lever on the floor, it might be something else--Check your owner's manual.


RON