I have an '08 F350, 6.4 L Diesel, 12000 miles. My wife and I are currently on our first extended trip with this vehicle. While pulling our 37' 5th-wheel toward Yosemite National Park in Ca, our Tow/Haul, 4X4 Low, and TCS lights all began to flash simultaneously while the truck jerked as if trying to engage 4-wheel drive. Ford had the truck towed to Lithia Ford in Fresno. They returned it two days later having removed and replaced the transfer case shift motor and contact plate assy. After about 12 miles the truck did exactly the same thing as before. It was towed back to Lithia Ford. After 7 more days, they returned it saying they R&R'ed the 4X4 module. We hooked up and headed north. After 300 miles the truck began the same behavior. It happened sporadically until 400+ miles. The truck is now at Crown Motors in Redding, CA. The service advisor told me last night that they have ordered a 4X4 actuator, but it will take a few days to get here. We have now been held up for 13 days with no end in sight. I left a message with the service advisor asking why they don't take an actuator off a vehicle in their inventory and replace it when the new one gets here, but he hasn't responded to my question. Has anyone else had this issue with their 4X4 system? Also, has anyone tried to deal with Ford during a trip interruption? I don't get a feeling that anyone at Ford is very concerned about our personal issues as a result of their vehicle not operating correctly. They make weak overtures about reimbursing me for my out-of-pocket expenses, but won't be specific or take the initiative. At least here in Redding the dealer provided us with a rental (limited to 150 miles/day).

 

Sounds like you got a lemon.

 

Welcome to FTE.

Mark could be right. I never like dealing with dealers. They always love to screw with you and charge more than you should be paying. :|

 

Douglj,
I am not famiular with this issue, but my family and I camp alot. We have a 30' fifth wheel. I have Good Sam's Emergency Roadside service. If you are not aware of it I suggest that you check it out. It not only covers your truck but they also cover your trailer. If you are stuck on the road they will come and get both and it's covered. They will also help with the costs of putting you up until the issue is fixed. Good Sam's will also go to bat for you with the dealer or with Ford Motor Company if it comes to that. They are a huge camper's organization, in their monthly magizine they have what they call the help line for situations just like yours. I would say 9 times out of 10 they get get what is fair. www.goodsams.com check it out

 

That sucks man, if you need any info while in Redding hit me up.

 

Are you sure it's trying to engage 4x4? With the tow/haul and TCS lights going, it sounds more like an ABS sensor (rear) issue than anything else.

Did they pull any codes from the PCM or ABS?

 

FWIW: I feel your pain.

> I left a message with the service advisor asking why they don't take an actuator off
> a vehicle in their inventory

You usually can't get that kind of service anymore, mostly because it requires effort and treating the customer like you want to be treated. I know, I have pulled parts off new vehicles for customers so they wouldn't have to come back or to get them on their way, even though you are not "suppose" to.

There are a few different ways to order parts. One is order and you pick up the next day at the warehouse or center (where the parts manager earns no % for stock returns) and weekly or bi-weekly stock orders (where the parts manager earns 2-4% for stock returns and spiffs). 13 days sounds like someone is not putting too much of a rush on those parts.

> Has anyone else had this issue with their 4X4 system?

Every OEM (Ford, Chevy, Dodge) has has issues with their "convient" automatic hub systems, some are worse then others. I have not dealt with the newer Ford ones, but, it sounds like to me you are dealing with the same issues Ranger/Bronco II/Explorer owners have dealt with since the mid 1980s.

Three times sounds like a lemon law suit waiting to happen. Document everything including call times, names, and conversations. If I were you, I would let it drag out a while so it was a good lemon law case.

Then return the truck and get a new truck at Ford's cost with a manual transfer case with manual hubs.

imho, A truck with a 4x4 system that does not engage 100% of the time is like using birth control that is only 95% effective.

When it fails that % of the time, you do regret the whole relationship.

 

I love Redding !
Good luck with your truck though