Tansfer Case #2...Grenaded Itself...(pretty sure)

You may have been on the right track with this idea (somehow I'm not surprised, Mr. Know it all ). I drove the truck around the neighborhood in 4x4 and it worked just fine. I shifted in and out with the switch a few times, all was well. Fastest I got going was just shy of 40. The original problem happened at almost 50mph. I didn't get a chance to check for bits of metal with a magnet.

I gave her some gas a few times to put load on it and it worked fine then too. I'm gonna go ahead and drive it to work tomorrow and see what happens.

I wonder what could cause it to not engage, or be slipping out slightly? The motor seemed to work fine, but maybe its movement is just fine but it isn't holding position.

On another note...I popped the old T-case open. Everything LOOKS perfect...and I mean the parts in there look like the truck just rolled out of the factory. Nothing is worn, no bits of metal in there anywhere, not even flakes. Chain looks fine, everything spins great. What was left of the fluid was a nice and clean. It's got me really confused as to why it was binding up and slipping out.

I'm really stumped now with both of these T-cases.

 

When I really think about it, had this thing "grenaded" like I first thought, it more than likely would have been making some noise in 2wd too.

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Sometimes those motors just wear out. It's alot more typical in Alaska when you're in 4x4 a quarter of the year. It takes alot to grenade a t case. Another thing is I know you've said you've had electrical issues before an it could be related

 

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Just bought one. There goes $130 that I really wasn't in the mood to spend, I hope it makes a difference. Fingers crossed.

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your truck is just a bad lemon im glad your not bashing the whole company

 

It really is I don't bash the whole company though because most people have good luck with their f150s, I seem to be the exception. My friends 97 has very few problems....we have 3 more fords in the family as well-an 02 sport trac, an 06 350 with the 6.0no, and that high boy I post here from time to time.

I attribute many of my trucks problems to the fact that the previous owner beat the truck up pretty good. It was obvious he didn't take good care of it, where as I do my best to make sure everything is good.

Of course a lot of it us due to the fact that it has 184,000 miles on it as well...I've put 60k on since I got it.

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