Transfer Case Question

My 2018 with 16k miles is in the shop after it broke down on me this past weekend while about 60 miles from home. Long story short, had to have it towed to the dealer where they told me today that it needs a new transfer case as it was locked in 4w low. Luckily still one year left on warranty so it's covered. After driving about a hour everything went wrong as soon as I pulled into a state park that had a pretty decent decline. Then after a loud grinding sound, it wouldn't go above 10mph. I am interested to know if anyone else has had issues with the transfer case and if so, what may have caused it? thanks!

Memphis Ken said:

My 2018 with 16k miles is in the shop after it broke down on me this past weekend while about 60 miles from home. Long story short, had to have it towed to the dealer where they told me today that it needs a new transfer case as it was locked in 4w low. Luckily still one year left on warranty so it's covered. After driving about a hour everything went wrong as soon as I pulled into a state park that had a pretty decent decline. Then after a loud grinding sound, it wouldn't go above 10mph. I am interested to know if anyone else has had issues with the transfer case and if so, what may have caused it? thanks!

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Transfer case is part of 5 yr/60,000 warranty. Not sure on your issue. Sounds like you were driving it in 4Lo in the State Park?

I had a weird thing happen to me when I couldn't shift out of 4L. Tried the old forward and back thing, no joy. The display said I was out of 4L, but it was obvious that the transfer case had not shifted. I cycled the ignition and everything was fine. I have no idea if it could be related, other than the computer and the transfer case disagreeing could be an issue. If something similar happened and yours was in 4H when it thought it wasn't and you were on the pavement, it would sure stress things.

Mine is in the shop right now. The front seal on the transfer case was leaking. They replaced it and the new one didn't fit. The housing was machined improperly. They're saying two weeks for a new housing and they haven't found me a loaner. Annoying.

smgilles said:

Transfer case is part of 5 yr/60,000 warranty. Not sure on your issue. Sounds like you were driving it in 4Lo in the State Park?

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Good to know that's it's part of the 5yr/60k warranty. I was driving it in 2H when the problems occurred. I just picked it up from the dealer and they said they have had a few (even a new 2020) with this transfer case issues recently.

Notes from the tech on the repair order - "Road test found transfer case stuck in low range. Checked operation of transfer case motor. Motor working properly. Removed transfer case and disassembled. Found excessive metal in case. Found damage to shift shaft and synchronizer. Replaced transfer case with new unit. Retest. Road test, ok.".

GordoJay said:

I had a weird thing happen to me when I couldn't shift out of 4L. Tried the old forward and back thing, no joy. The display said I was out of 4L, but it was obvious that the transfer case had not shifted. I cycled the ignition and everything was fine. I have no idea if it could be related, other than the computer and the transfer case disagreeing could be an issue. If something similar happened and yours was in 4H when it thought it wasn't and you were on the pavement, it would sure stress things.

Mine is in the shop right now. The front seal on the transfer case was leaking. They replaced it and the new one didn't fit. The housing was machined improperly. They're saying two weeks for a new housing and they haven't found me a loaner. Annoying.

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Sorry to hear that the new one didn't fit but hope that yours is covered by warranty as well and gets repaired soon! They did give me a new ford ranger loaner which was good because I only have the one vehicle.

I have a Gen 1, but suffered the exact same situation. Shift into 4L and drive a bit, thensthen back to 2H process, lots of grinding and no engagement. Engine revved freely. Turned off, restarted and was back in 2H, but transfer case was done. Thankfully, extended warranty covered all those shredded metal bits and I have a new transfer case.

I have a 2011 6.2L GEN1, and had to have the transfer case replaced. Warranty had expired, and it wasn't cheap.
Symptoms: On and off wrench warning on the dash, and it intermittently would not engage in 4H. No unusual noises or behavior other than that.
Took it to the local dealer, and in the process of diagnosing the problem they managed to thoroughly break it so that it was stuck in 4H. I couldn't drive over 60mph (I kept it well below that) until the new transfer case became available. I asked if the new unit was exactly the same as the old one, and was told that it was an improved model with fewer plastic internal parts. They told me that the shift fork on the old one was plastic, and that the new one had a metal shift fork.

If you have to get your transfer case replaced, check the fluid level as soon as you get it home and it cools down. My new transfer case was 7 ounces low. I also recommend that you change the fluid after 1,000 miles.

just FYI gen 1 teansefer case replacement is a walk in the park! I changed mine in less than 2 hours! Was amazed at how simple it was!

Kirkw said:

I have a Gen 1, but suffered the exact same situation. Shift into 4L and drive a bit, thensthen back to 2H process, lots of grinding and no engagement. Engine revved freely. Turned off, restarted and was back in 2H, but transfer case was done. Thankfully, extended warranty covered all those shredded metal bits and I have a new transfer case.

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*transfer

Also was very inexpensive! Bought a rebuilt unit for 980 with core charge