I have a 2006 4x4 f150 with 5.4 V8. I just put a 6 inch lift and 35s on it. It had 3.55 gears stock, and I put 4.56s in it when I lifted it (I had them professionaly installed). The gears are made by Motive. As soon as the new gears were put in, my truck started making noise in 4x4 high and low, but not in 2 wheel drive. I only have about 350 miles on the gears, and I just discovered that now I can't shift into 4x4 low at all, but 4x4 high still works and still makes the same kind of light grinding noise (sounds similar to a bad wheel bearing or something like that). I called Motive, and their technician siad he's almost 100% sure it's a transfer case problem that wasn't noticeable until the 4.56s put a little more stress on it. Anybody know what this could be specifically, and can I get upgraded aftermarket replacement parts so this doesn't happen again?
Thanks for any advice

 

Maybe a rebuild kit or something like that that's better than the stock components?

 

That does not make any sense, 4.56 gears will put less stress on the transfer case than the 3.55 gears did by far. Your transmission and transfer case should be working with less stress accross the board because of the gears.

 

I don't know what happened involving the transfer case. I know it hasn't been removed or tampered with. I installed the lift, and I didn't touch the transfer case. I took just my axle and front diff. to the shop to have the gears put in, so I know they didn't even see my transfer case. The noise started immediately after the gears were installed

 

You got the Fabtech kit right? Did you have to alter the front drive shaft, don't you have to take it apart and rotate part of it and put it back together. I have a fabtech manual, I will take a look at it.

It is only happening in 4wheel drive it could be that or it could be you solenoid messing with your front actuators, that is a 25 dollar fix, I would start there.

I have never seen a transfer case go like that....

 

Yeah I have the Fabtech 6 inch kit. The u-joint on one end of the front drive shaft had to be rotated 90 degrees to line up with the other u-joint. I don't know what's going on with it. I went by a transmission shop today, and they really can't tell me anything without taking it apart and looking at it, which costs a lot in labor

 

How would I check the solenoid?

 

not to sound pushy but get rid of the motive gears and go to yukons or frpp gears

the motive gears are notorious for making alot of noise

 

It's the transfer case making noise, not the gears

 

That is a dumb comment. Motive, G2 and Yukon gears are all made in the US with US steel. There is not that much of a difference in quality. I am sure that he Motive gears are fine and I have G2 gears and they are fine as well.

Don't test the solenoid, just pull it off and repalce it, it is directly behind the battery and only costs 28 dollars. Get the one with the hood that covers it up. Mine failed directly after I lifted the truck and I trouble shot for a few days before just swapping it out. Start there, it is the cheapest...