Hey guys, I have been reading up on the transfer case rattle and i THINK i have fixed my problems. I have a 2008 Ford F150 XLT 4x4 automatic 5.4 3v with the 3:73 axle ratio. Supercab btw. Anyway, this rattle/sound sounds alot like the starter sticking so i replaced the starter. Still does it and its very very random. I have spent over a hour under the truck with tools and wrenches testing the tightness of each and every bolt on EVERYTHING. Heatsheilds are ALL tight. I moved back to the transfer case and put my hand on the transfer case drive shaft, the one that goes to the front axle from the transfer case. I was able to easily rotate that shaft probably a 1/4 turn and i heard a click and it was done turning. This was all done in 2hi btw. Rattle is gone and the truck is in 2hi, the icy roads around here proved it! 4hi works ok..it takes a while to get it in 4hi and OUT of 4hi. My truck is under a extended warranty, which has proven to work out great. The rattle is LOUD and only in gear, in park or neutral its gone and coming to a stop you can tell the rattle is a rotating rattle, like a tire going around and around. I just wanted to ask you guys, i have seen only a few posts like mine, but i just want all the knowledge i can get from you guys before i use my warranty to fix this, which hell it may be fixed now? i dont know what that turn of the shaft to a click meant but the rattle is gone for now..4hi works fine 2hi works fine. Me and my wife tried to make a video, i was under the truck with her in the truck with it running and in gear and nothing. Heck maybe its fixed?! I would love to know what that click meant. Any help is appreciated

 

Any help would be greatly appreciated

 

Did you ever think of banging on the exhaust system with your fist or a rubber mallet?

Sometimes loose exhaust equipment will make rattling sounds, which can be only at certain times.

 

I haven't a clue .... but I was very interested to read if anyone else did.

 

oh yes...i ruled out the exhaust when i heard this rattle sound have a turning sound to it when coming to a stop..after i turned the 4x4 driveshaft, everything is fine now, its weird...if it happens again its goin into the shop because i have a extended warranty..but yeah, manifolds are tight, mid pipe is tight, cat back is tight so i have pretty much ruled out the exhaust...had to have been the transfer case or front axle or something......one guy said it was the IWE?? i am lost with these 04 to 08's

 

IWE?

https://www.f150online.com/forums/ar...then-some.html

 

Thank ya sir!! GLC that is...no my problem hasnt came back at all since i rotated that shift till it clicked...4x4 goes in great and comes back into 2hi great..i talked to a guy that works at the dealer and he said something about the transfer case wasnt aligned right...who knows! Be safe! Joplin isnt too far from where i am and im sure your gettin the ice just like we are

 

We lucked out - there is very little ice here, you can't even see it in the trees and the streets are fine.

 

oh wow, good deal yeah i guess friday i70 had some pretty bad wrecks..anyways thanks for your link and if i have anymore problems i am going to use my warranty and let uncle henry (ford LoL) fix it, be safe and take care!

 

see my recent post on the IWE system and how it sounds

 

Thanks for the help, I think my 4x4 didn't disengage all the way and I turned the shaft by hand which may have totally disengaged the 4x4