I drive a 1997 f150 rcab 4.2 lit. 4x4 with a 5 speed.. When pulling a boat yesterday up a steep, muddy hill and again on another steep rocky hill, I switched into 4 low. The clutch (new) was fully engaged but I smelled a burned rubber smell and heard a clicking or grinding from either the transfer case or the front end. It should have been fully engaged in 4 low as I had backed down the hill in 4 low.
Is there a belt to slip in the transfer case or is the switch not fully engaging in 4 low?? There does not seem to be a noise in 4 high under load.
Thanks, Machted

 

Nobody with any input? I would like a little education before hitting the dealership. The truck does not have the electronic 4x4 shift. Thanks

 

Will you be able to recur the sounds/smell for the tech? You may need to bring the boat and find a hill.