Hoping to find someone that can point me in the right direction with a recent issue I've had on my truck.

2006 F-150 lariat (bought new), 5.4, 4x4 electronic shift, 82k miles.

Yesterday while driving home from work I noticed some minor grinding sound on what sounded like the passenger front wheel. I was about 1/2 mile from home so of course I parked it until I could figure out what was going on. Based on other reviews here I was thinking…IWE, not too big of a deal. After a jacking up the truck today It doesn't seem to be an IWE problem as there is no noise when turning either front wheel, and the axle shafts spin when they are suppose to and don't spin when 4x4 not engaged. I lowered the truck and was planning on driving around the block to listen to the sound again. This is when more issues arose.

I put the truck in reverse. I could hear the transmission shift normal, but when I released the brake the truck did not move. I gave a little gas, and felt a huge bind at the same time the truck launched reward then seemed to slip again. I stopped. Out of curiosity I shifted to 4Hi. There was an excessive delay shifting. I put the truck in Drive and no issues going forward except the transfer case sounded like it was about to blow up (clunks and bangs). I stopped and returned to 2Hi. A few moments later I shifted to neutral, attempted to shift to 4Lo. The transfer case never switched to 4Lo, but did switch to 4Hi. I could hear the transfer case continually clicking (the sound it usually makes when shifting), but it never made it to 4Lo. I went back to 2Hi, put the truck in gear and again felt something binding in the truck. At this point I put it in park and decided it will have to either sit until I can figure out where to start, or worst case scenario towed somewhere.

Has anyone experienced anything like this? It sounds like something in the transfer case is screwed up. Is there hope for any easier (cheaper) fix?

Thank you for any leads you guys can provide!

Jeremy

 

Forgot the basics. No codes found on my scanner, no check 4x4 lights

 

Ended up sending the truck to the shop. Got a call last night the the drivers side front drivers side axel was trashed (metal shavings everywhere), About $500 later, the truck should be ready for pickup today. Need to figure out what caused the damage. When I go in today to pick up the truck I'll try to grab some pictures. Any idea what would cause this? Ford dealership says everything else is fine, just the axel itself. I do have a 2.5" AS spacer, I know this can cause boot issues, but is it possible it can cause complete axel failure? Still unsure of where the axel failed. More details to come.

 

Not sure if anyone is interested, but I finally have the truck back home and all is well, minus the pain to my savings account. SO…the axle was not the problem after all. I picked up the truck after the axle swap, didn't even make it out of the garage, and noticed the binding was still happening. Apparently the dealership didn't road test my truck after the axle replacement. They dropped the transmission pan and there were 4 pieces of metal the size of my pinky finger, and a ton of metal shavings. After a transmission swap, I'm back on the road. I was just thinking of picking up a left over 2013 FX-4, right before this happened, now I'm going to be enjoying my very expensive transmission for many years to come :-)

 

Yes,we are interested. Just didn't have any suggestions from you initial post. Thanks for posting back with what fixed it. Hope it gives you lots of trouble free miles now.