First post, switched on my 4x4 the other day and got a clicking sound for about 2 seconds. 4x4 went in with not any other other noise. I got under the truck and had someone work the switch on and off (dash switch) The relay seemed to be working fine, and sounded like it always does. The truck is a 2003 F-250 SC w/ 39K about 6-8 hours on the 4x4, truck is awesome has the 5.4 and runs great. Last used the 4x4 in March for about 10 minutes and it was fine. As you can see I don't drive the truck too much. Has anyone had this happen, any info would be great. Thanks!

 

Not sure what the clicking noise was but the aluminum sleeves around the 4X4 is prone to corrosion. Both my dad's and my manual lockouts turn anymore but our shift on the fly still works fine. Might be that, I was told to simply engage the 4X4 about once a month to make sure it doesn't seize up.

 

Thanks madcowracer, I have always put on the 4x4 every month or so. Not sure if I did since March. It took me back when I heard the noise. This has always been a seamless thing to do with this truck. I'll work the system the next few times I drive the truck to see if something is sticking or something. Thanks, anyone else have to deal with a little clicking sound when putting on the 4x4? Not sure if the gears hit each other before going together or what.

 

Were you moving or standing still when you heard the clicking? Mine will make that sound sometimes when I'm not moving, although I can't usually hear it if the engine is running.

What is happening is the gears are not meshed, so they click when they come together, then the computer realizes the shift wasn't complete, so it moves the servo back to 2wd and tries again. It'll try 4 or 5 times until the shift completes, or if it doesn't then it gives up.

 

Thanks, I was moving about 40 mph.

 

Were your front hubs locked? And when they aren't, do the axles spin free?

 

Krewat, The hubs were set on auto. I checked the front drive shaft and it was free after I went back into 2wd. But it seems like the axles do still rotate even with the hubs are in auto and in 2wd. So the odds are that this was the condition when I tried the 4x4 when it made that noise. Thanks.