4wd problem clunk/grind when engaged - Ford Powerstroke Diesel Forum
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Old 05-16-2013, 12:32 PM
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4wd problem clunk/grind when engaged

Hey guys, I'm pretty much a newb here but I've done a bunch of searching and havent found my particular problem....

I have a 2008 6.4 with ESOF switch on the dash 4wd

I've never beat on the truck in 4wd, only use it when I really need it.

Hardest it has ever worked has been pulling out stuck people and trailers out in the California sand dunes at Glamis.

Truck has 70k miles

4wd has always worked flawlessly even right up to the moment I started having problems. I needed 4wd just 20 min before and had no problem, then i disengaged it into 2wd and worked fine. Then the 20mins later I needed 4wd for nearly the same situation, was not moving, while in park, i put it into 4hi and the light indicator indicated 4wd engaged but it made a terrible clunking noise with some grinding involved when driven forward. I put it into neutral and tried 4low and the same thing happened.

Throw it back into neutral and put it back in 2wd and it takes 10 or so seconds but finally disengages enough to go back to 2wd and drives fine.


Do you guys think it's the Front hubs, the actuator motor on the transfercase, or are the guts in the transfercase fubar?

Or is there a logical order to test and rule out one or the other? The noise is terrible and I wouldnt want to hurt anything in the testing.

could I put the entire truck on jackstands and test while the wheels are up in the air to minimize damage to the internals?

thanks for your help!

And heres a pic - 8" lift and 40's on 24's



Ken
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Old 05-22-2013, 02:59 PM
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Looks like I'm by myself on this one - I'll let you know how I fix it
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Old 05-22-2013, 04:42 PM
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Send a message via MSN to pudil45
Usually u joints


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Old 10-08-2013, 09:06 AM
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Finally got my lazy head up under the truck (it sits for long periods of time since it's just my tow/fun vehicle)

Found the problem - I'm thinking sabotage unless this is a common problem...
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