I have a 2006 F150 with 2500 miles. My problem is that it won't go back into 2wd. I have tried it in neutral, park, drive you name it. As I try to move back to 2wd it immediately starts to grind. I finally have to shut the truck off and get it back into 2wd. I will be taking it back to the dealer but wanted to no if anyone else had this problem and what it was. Thanks Joe

 

What do you mean, 'move it back'? Move what back?

Where is the grinding coming from? Does shutting the engine off stop the noise? Try changing from 4 to 2 with the key on but the engine off. Any change?

We need more info before we can make even a semi-educated guess.

 

I had that same problem but mine wouldnt switch out of 2WD they said i had a bad line

 

When I try to move the shift selector on the floor from 4 low back into 2hi it sounds like the flywheel is grinding. It does it about half of the time. Like I said neutral with the brake, in park with or without the brake any combination and I have tried it. I just wondered if anyone else has run into this on a new truck. Thanks Joe

 

Some noise when shifting with the manual lever is normal. Every transfer case I have had with a manual lever did it. Don't know whether it is the speed difference between the ESOF motor moves it or what, but every manual shift 4x4 I have had made noise when shifting. It even said in the owners manual that some noise was normal.
Is it truly not coming out of 4x4? Does the indicator stay on 4hi?

 

OK, so that's the weird thing.... With the manual SOTF (and even the electric SOTF), the only thing that moves between 4high and 2high is the lockup collar disengages and the hubs unlock. I could see it doing that if you're driving, but stopped and in neutral, nothing in the transfer case should be moving, therefore nothing should be grinding.

Now, from 4low to 4high and back, you must be stopped, in neutral, with your foot on the brakes. The high/low shift requires everything be stopped so that the planetary gears can mesh/un-mesh. You cannot shift into and out of low range on the fly, only between 2high and 4high.

Now, if it's still doing it stopped, in neutral, foot on the brakes, there's something weird going on in the transmission, and I'm not sure what it could be. In neutral, once you've stopped, the transfer case has stopped as well. As you move the lever between 4low and 4high, you cross neutral, and if everything is working the way it should, the input shaft of the t-case and output shaft on the trans should also be stopped to allow the shift. If it starts to move while you're in neutral, it'll grind. Same if the vehicle starts to roll.

Try it out again and let us know. Again, stopped, in neutral, foot on the brakes, then shift between 4low and 4high. Only shift on the fly between 2high and 4high.

 

I also had some occasional grinding problems. Put Mobil One tranny fluid in the transfer case and have not had any moreproblems.