Hey yall,
Posting for a friend without an account, from ford-trucks.com, "I have a 2004 f150 single cab stepside fx4 w/ the 5.4 and 4r75w. I believe I have the BW4406 Transfer case. Just bought the truck and tried to use 4x4 for the first time and it will not lock in, however the lights on the dash operate. The transfer case motor works properly and the shift mechanism is moving. Went put in 4x4 and rolling forwards you can hear the gears ticking as they slip past eachother, the hubs lock in fine but theres no power to the front as the gears wont engage. I think the internals are shot as if it was maybe run on the street and the gears are sheared. In reverse it does not tick/click as the gears are meshed, but if any power is applied they slip.
Is this a more simple problem such as a internal adjustment of the gears so that they mesh or is it like I think and its shot? Where can I buy a rebuild kit cheap? A complete new Tcase is around $480 but i'd prefer not to have to just junk the whole thing.
Thanks in advance

EDIT: 4lo and 4hi have the same result. I removed the shift motor and its moving to the proper places for each engagement so that isnt the issue."

thanks yall

 

so is he saying the gears on the front diff are sheared?

 

Well that's what I think. We took the motor off and its moving where it needs to fine, and it definately sounds like the gears are just barely kissing but no power transfer. Do you know what would be messed up, like what things we need to replace? I ask because this is a daily driver, can't have it apart for a long time while parts come in

 

first thing i would do would be to take off the front diff cover to check and see if anything is wrong.

 

Will do, but I definately don't think that's the issue.