Transfer Case Failure at 21k miles
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Tuned
Joined: May 2014
Posts: 317
Likes: 16
From: Richmond, VA
Transfer Case Failure at 21k miles
Hello everyone! I just purchased my '25 Powerboost back in July. 21k miles later, I had a noise in the front that reminded me of when my '05 F150 had a bad wheel bearing and IWE. Took the truck in for diagnosis and found out my transfer case is bad.
Dealership has an estimate for 3 days for parts, and they won't dig in to the exact diagnosis until the parts arrive. Has anyone else experienced a transfer case failure this early? What was the cause?
I've also learned that with the '24 refresh, the trucks with the "full time (4-auto)" transfer case no longer have IWE's. Front end is completely engaged at all times, and engagement is 100% handled by the transfer case. So I supposed we've traded eating hubs and IWE's for eating transfer cases now.
*XL & XLT trucks with the 2-speed part-time transfer case (no 4-auto) still have the electronic IWE's.
Dealership has an estimate for 3 days for parts, and they won't dig in to the exact diagnosis until the parts arrive. Has anyone else experienced a transfer case failure this early? What was the cause?
I've also learned that with the '24 refresh, the trucks with the "full time (4-auto)" transfer case no longer have IWE's. Front end is completely engaged at all times, and engagement is 100% handled by the transfer case. So I supposed we've traded eating hubs and IWE's for eating transfer cases now.
*XL & XLT trucks with the 2-speed part-time transfer case (no 4-auto) still have the electronic IWE's.
Tuned
Joined: Mar 2005
Posts: 335
Likes: 6
From: Ames, Iowa
We have 15 of these trucks in our fleet, which are not exactly babied, and we have had 0 transfer case issues. Only a handful of these trucks are 2021+, but overall, we have had no issues. IWE's though, I HATE them.
My fleet truck is a 2024 and it has almost 27,000 miles on it. It has been perfect, until I got a software update over the air a couple weeks ago.. Now the transmission has a very rough shift (I think it is 3-4) until it warms up completely. Otherwise, it's a great truck.
My fleet truck is a 2024 and it has almost 27,000 miles on it. It has been perfect, until I got a software update over the air a couple weeks ago.. Now the transmission has a very rough shift (I think it is 3-4) until it warms up completely. Otherwise, it's a great truck.
Mountain Pass
Joined: May 2025
Posts: 181
Likes: 115
I'll wager it's not the transfer case but will end up being spun bearings in the front diff requiring case replacement. They've probably heard noise in the case and front driveshaft has some vertical play but the noise will remain after replacement. Hope I'm wrong
5th Wheeling
Joined: Apr 2012
Posts: 38
Likes: 0
From: Santa Paula, CA
Had my transfer case explode on my '22 with 50k miles. Tranny went bad so i took it in for replacement. Got it back and the steering wheel was vibrating. Let the dealership know and said give the tranny a week and if its still doing it bring it in. 3 days later exploded while driving down the highway. Smoke in the cab and dumped fluid all over the road. Had to get it towed in. Covered by warranty. Pain in the ***.
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Tuned
Joined: May 2014
Posts: 317
Likes: 16
From: Richmond, VA
Update.
40k miles on the truck, second transfer case has left the chat. Same symptoms, same diagnosis, new part number on the replacement transfer case.
1500 miles on the new (third) transfer case, now it's making the same sound plus and ominous "thunk" when I accelerate and decelerate.
40k miles on the truck, second transfer case has left the chat. Same symptoms, same diagnosis, new part number on the replacement transfer case.
1500 miles on the new (third) transfer case, now it's making the same sound plus and ominous "thunk" when I accelerate and decelerate.
Last edited by jerryparks; Yesterday at 06:15 PM.
Tuned
Joined: Apr 2015
Posts: 274
Likes: 67
From: N.E.Indiana
Well that's painful just to read, I can't imagine. I have no "light bulb answers" but there has got to be something else going on. No one is unlucky enough to have 3 trans cases puke. It's sad that we are reduced for the most part to techs that are parts changers with few actual mechanics left to diagnose things. Jim
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