I had the same problem several years ago. The steel cable on the vacuum actuator (located under the battery tray), was broken (internally) at the transfer case. I had to wait 2 weeks for a factory replacement. Dealers were not permitted to stock and had to supply the VIN no. of the vehicle before ordering. Apparently this was a very common problem. Another cause of the same problem was the electrical switch on the side of the transmission (hard to get to). The ball actuator sticks. Each part costs about $30.00. Hope this helps.
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AWD vehicles have a centre diff in the transfer case and if there is no traction on the rear wheels then the front wheels will not turn. All wheel drive is not equal to 4 wd which you assume apparently. Check that there is not a diff lock button in the car to lock the centre diff turning it into 4wd vehicle in which case the front wheels would have moved the vehicle
I believe that is standard for a stock 4X4, If you have true posi 4X4 all 4 wheels will turn at the same time in your case when the 2 spinning wheels spin under load the other 2 kick in
hope that helps you
The item that is in operation when in 2 WD is a spigot bearing on the shaft between the drive shaft and the output shaft into the transfer case. IT stops working when the gear connects both shafts together as in 4 WD. It was a common problem if the 4WD drive is seldom used as this bearing gets little lubrication as one shaft is spinning and the other is not
I had a 4x4 year ago. Do you have front locking hubs ? I don't think so if you did I would ask if they were in or out. If there is nothing else It has to be coming from the transfer case. As far as I know no manufacture makes a true 4 wheel drive but Jeep except for maybe Raptor or Power Wagon. Most come with an open diff in the rear one wheel drive unless you order it special and the front you can't even order a locker if you wanted to 99.+% of 4x4s have open diffs in the front. Jack up one front wheel and one rear wheel if you didn't order a special rear end if you try to drive off the jacks you will sit there and spin your 2 wheel drive and not move.Ford says if you have worn tires or not the same air pressure in all tires it will do this. I think you have a bad u joint or pieces broken in the transfer case or it is out of adjustment. Jack car up like I said before and when the wheels spin without pulling it off the jack stands crawl under and see where the noise is coming from front or transfer case.I wonder if your shift motor could be bad they are about 65 dollars
Slow? Depends on what you are pulling? Is it just the truck itself? Or are you trying to pull a backhoe? The only thing you will disconnect on the transfer case is the propeller shaft, and it will run fine, but I don't think you will gain anything by it. The transfer case does nothing till it is engaged, it doesn't even spin, the power goes through to the rear, untill you put it in 4 wd, Hope this helps.
Having 4 wheel drive is not actually the case unless you have limited slip on both axles. Do you know if one wheel will spin on both axles. If you can't get either wheel to spin on the front axle and one will spin on the rear then I would agree your not getting front wheel drive. Since you can tell a difference between hi/lo the transfer case is definitely engaging
It does not seem that sufficient diagnosis was done. No, you cant give a specific diagnosis like that without tearing unit down. It's likely that they told you the most common failure and left it at that. Likely there is a problem with your unit...I think this becomes more of a trust issue than a mechanical one. A second opinion from an independent reputable shop may help but either way, you need to have it fixed. In not using it much, it makes me wonder how it got worn. good luck
OK If you have manual locking hubs, one could be acting up. Jack the rear wheels off the ground and block the front wheels. Be sure you have the trucks back axel supported, not just on jacks! Then, with a person in the drivers seat, put it in gear. The 'driver' will turn the steering from lock to lock, while you check [from outside the truck, not under]] for the shaft at the front wheels that is spinning. This is the prob ! Frankster016