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Transfer Case Problems of Ford F-150

Ford F-150 owners have reported 23 problems related to transfer case (under the power train category). The most recently reported issues are listed below. Also please check out the statistics and reliability analysis of Ford F-150 based on all problems reported for the F-150.

car image   Transfer Case problem of the 2015 Ford F-150 1
Failure Date: 07/11/2017

This took 4 attempts and 2 dealers to resolve - ~34k miles- loud grinding/vibration from front left 4x4 hub when driving any speed. The first dealer had the truck for 6 days and claimed they didn't see or hear the problem. The second trip to the dealer they had for a few more days and said they fixed it. On the way home it was obviously not fixed and I turned around and took it back. Again after two days they said it was fixed yet it was not. I then took it to a different dealer and they knew what the problem was and fixed it. They also informed me the service log didn't show any service attempts to the truck so my truck sat for almost two weeks and no work was actually done and I was lied to. Second issue - not resolved. Life of vehicle - wobble/vibration from 4x4 transfer case that intensifies with increased speed. Driving in 4x4 low at all speeds you can feel and see the steering wheel shake, even going as slow as 10mph. The steering wheel, seats and peddles shake as if the tires aren't balanced. I have installed 3 different sets of tires and it still shakes. 2 different tire shops verified the tires are good and the alignment was good. The shaking isn't bad like the death wobble but doesn't feel safe. It shakes enough that my 3 year old gets sick to her stomach from the bouncing. Third issue - resolved with my money - at about 45k miles the factory front rotors were worn to the point of replacement due to deep cuts. This occurred with the factory brake pads.

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car image   Transfer Case problem of the 2012 Ford F-150 2
Failure Date: 07/11/2016

I have shuddering goin on somewhere in the drive shaft, transfer case and the transmission. I just got it back from Ford where they told me they could not fix it. And on the way home I hit a bump on the highway and the shudder almost ran me into the car next to me. I am feeling very scared to drive it, I feel like it's gonna fall apart. I've had it into Ford many times for this problem and others and to no avail, they can't fix it. I'm ready to file a lawsuit over this. Please help. Thanks.

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car image   Transfer Case problem of the 2015 Ford F-150 3
Failure Date: 12/03/2015

New 2015 f150 with a vibration/ shudder coming from what feels like the transfer case or possibly the drive shaft. Happens when trying to shift from gear to gear, and on inclines. . . Feels like it is going to stall. Also happens when just cruising at certain speeds. I've had it to the dealer twice and they say everything is fine but they have felt the same problem with this vehicle and ones on their lot. Vibration could lead to more serious problem and actually stall the vehicle while in traffic.

car image   Transfer Case problem of the 2005 Ford F-150 4
Failure Date: 06/30/2015

I was driving and heard a sound come from my engine compartment. I didn't lose power, but pulled over to look under the hood. Not noticing anything obvious I checked the fluid levels and noticed that my transmission fluid was low. It had been checked two months prior during oil change. I had no visible signs of leaks. I found a forum on the internet that talked about transmission fluid going from the transmission to the transfer case, but unable to return. They had a $20 seal replaced under warranty. The forum had stated that this was a known condition but nothing was being done by Ford motor company. A mechanic had said that it only effected 17-18% of vehicles manufactured between 2004-2008. I called two local dealerships and they knew the problem but said that there was no recall on it. It takes approximately 3 hours to change, by dropping the transfer case and replacing the seal. I called Ford motor company representative and was told that there wasn't a recall and that they couldn't help. I feel that this could result in a premature failure of the transmission and possibly a catastrophic event. I was told by fmc rep that should a recall occur I could take my receipt to a dealership and that they would possibly reimburse me. I don't feel that Ford should have a known condition but do nothing to correct it. Please look into this for me and others under the same situation.

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car image   Transfer Case problem of the 2005 Ford F-150 5
Failure Date: 08/01/2014

The contact owns a 2005 Ford F-150. The contact stated that while driving at approximately 25 mph, the four wheel drive activated independently as a loud abnormal noise emitted from the front of the vehicle. The failure occurred on numerous occasions. The vehicle was taken to a dealer where it was repaired on numerous occasions but the failure persisted. The repair specifics were not available. The manufacturer was notified of the failure. The approximate failure mileage was 58,000.

car image   Transfer Case problem of the 2010 Ford F-150 6
Failure Date: 02/01/2012

2010 Ford F-150. Consumer writes in regards to transmission problems and gross neglect of customer service at dealerships. The consumer stated the vehicle has been in the repair shop on four separate occasions, for transmission and four-wheel drive issues, which has yet to be remedied. The dealer acknowledged there was a problem, but they didn't know how to fix it. The consumer stated while driving between 25-30 mph in heavy traffic, the vehicle made a terrible sound and when he put the vehicle in 4-wheel drive it made no difference. The consumer was informed the vehicle needed a road force balance. The road force seemed to help slightly, but only for a brief time. When he returned to the dealer, he was then told the drive line needed to be aligned. After having that done, the vehicle continued to operate in the same manner.

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car image   Transfer Case problem of the 2003 Ford F-150 7
Failure Date: 12/18/2010

The contact owns a 2003 Ford f150 4wd. The contact was driving approximately 2 mph in inclement weather when the contact drove over snow and the vehicle began to spin uncontrollably. The contact then engaged the accelerated and noticed that the vehicle was in four wheel drive but the four wheel drive would not activate. The vehicle was not taken to the dealer for the failure. The manufacturer was not contacted. The failure mileage was 72,000 and the current mileage was 72,200.

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car image   Transfer Case problem of the 2003 Ford F-150 8
Failure Date: 12/10/2010

The contact owns a 2003 Ford f150 4x4. The contact stated that while driving approximately 30 mph, the fwd engagement gear would not shift into place when driving in icy conditions. The vehicle was inspected by a dealer who informed the contact that he would need to replace the actuator for the gear shift. The vehicle was not repaired. The failure mileage was approximately 51,000. Updated 02/09/lj the consumer stated the vehicle was repaired. Updated 05/06/11.

car image   Transfer Case problem of the 2005 Ford F-150 9
Failure Date: 08/02/2010

The contact owns a 2005 Ford F-150. The contact stated that when driving at various speeds, the vehicle would attempt to shift into four-wheel drive independently. The vehicle was taken to an authorized dealer where it was found that water was leaking through the front chassis in front of the four-wheel drive and corroding the solenoids. The dealer ordered the necessary parts to repair the vehicle. The failure mileage was 60,000 and the current mileage is 83,000. Updated 11/10/10.

car image   Transfer Case problem of the 2005 Ford F-150 10
Failure Date: 02/15/2009

The contact owns a 2005 Ford f150. While driving 2 mph in reverse the tires began to spin around and the 4 wheel drive did not activate. The failure has occurred twice. The vehicle was taken to the dealer and the 4 wheel drive was repaired the first time in Jan 2009. . The failure mileage was 38000 and the current mileage was 48000. Updated 4/13/10 the consumer stated the second time it was repaired was in March 2000. Updated 06/18/10.

car image   Transfer Case problem of the 1997 Ford F-150 11
Failure Date: 01/10/2009

The contact owns a 1997 Ford F-150. The contact stated that the vehicle would kick in and out of 4-wheel drive. While driving less than 55 mph, the steering wheel became stiff and the 4-wheel drive became inoperable. The 4-wheel drive warning indicator illuminated on the instrument panel. The dealer could not duplicate the failures. On a separate occasion, the failure recurred. The dealer advised the contact not to shut off the engine. They replaced unknown modules in the transmission at the cost of $607. The dealer also installed a new dashboard switch at no cost due to the fact that the vehicle had been there four times with the exact same failures. The current and failure mileages were less than 53,000. Updated 04-24-09 updated 04/27/09.

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car image   Transfer Case problem of the 2007 Ford F-150 12
Failure Date: 08/02/2008

I have a Ford F-150 4x4 super crew that is making a roaring/grinding sound from the front end. It only does this occasionally. Prior to stopping the sound will stop and the transfer case will make an engaging sound as though the four wheel drive is attempting to engage. I took it to the local dealership and they could not make the problem reoccur. I have a friend with an '04 F-150 4x4 and his is doing the same thing.

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car image   Transfer Case problem of the 2003 Ford F-150 13
Failure Date: 12/08/2007

The contact owns a 2003 Ford F-150. While driving 50 mph in snowy conditions, the electronic 4-wheel drive disengaged and shifted into 2-wheel drive without warning. As a result, the rear end of the vehicle fishtailed. The instrument panel indicated that the 4-wheel drive was activated. The dealer stated that they would install a new shift fork kit made with different material. As of December 13, 2007, the dealer had not repaired the vehicle. The current and failure mileages were 53,000.

car image   Transfer Case problem of the 2003 Ford F-150 14
Failure Date: 03/16/2007

2003 Ford f150 4x4. A heavy snow storm hit northeast on 3/16/07. I had my pregnant wife and three year old son in truck coming back from a doctors appointment. The four wheel drive did not engage. We were stuck for a long period of time. I did some research and this seems to be a common event with the Fords and there shift on the fly 4x4 system. I called Ford and they said they were aware of the on going problem but told me it was my problem. There were no recalls for the system and again stated "it was my problem!" there are many documented occurences yet nothing has been corrected. Truck is going in for repair on Friday and mechanic stated it is approx $500 to repair. The vacuum soleniod and vacuum lines need to be replaced. Ford was also aware of the vacuum problem when I spoke with them. Very frustrating and dangerous with a family relying on a 4x4 when needed.

car image   Transfer Case problem of the 2004 Ford F-150 15
Failure Date: 02/22/2006

I bought the 2004 fx4 F-150 super cab in late 2005 with 25000 miles on it. I purchased a $1400 extended warranty from an independent company through the Ford dealership. After the first few months I noticed a grinding sound under the truck that sounded like a few ball bearings rolling around quickly in a metal bowl. It would last about 5-10 seconds and then I would not hear again for a few months. After about the 5th time this happened I took vehicle to the Ford dealership, and they could not duplicate the problem, so nothing was done. The next time this noise was heard I quickly turned on the 4x4 high via the switch on the dashboard and the noise went away immediately. I could do this every time after. This was telling me it was somewhere in the transfer case. So, last week around 60000 miles the transmission started grinding in traffic, slipping, and giving me a transmission fail indication where the odometer was located , and a flashing overdrive off. This happened for about 10 minutes until I could get off the expressway, and exit into a gas station parking lot. I thought for sure the transmission was going to blow out at any moment. I turned off the truck, which reset the transmission fail alarm, put the truck in reverse, which made a loud slamming noise. I then put it in drive and was able to drive home with only grinding noise in first gear. I waited 2 days ,and then drove the truck to the dealership 40 minutes away without any problems . After a day in the s repair shop they pulled the pan and it had metal shavings everywhere. They called and told me they couldn't figure out how I was able to drive to the repair shop. They found some bad seals and a vacuum pump/solenoid in the transfer case, the transmission was gone and was completely replaced. All the software has been updated, which I have heard can cause the majority of the problems. It would have cost me around $6000 if I didn't purchase the complete warranty.

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car image   Transfer Case problem of the 1998 Ford F-150 16
Failure Date: 11/04/2005

The contact stated while putting vehicle in four wheel drive it accelerated unexpectedly. The accelerator pedal went all the way to the floor on its own. The vehicle would not shut off. The contact had both feet on the brakes, shifted into low, and attempted to shut off the engine. The vehicle went over a pedestrian, a ramp, and knocked the trailer through the tailgate. There was damage to the ramp and the vehicle. The pedestrian received only minor injuries, mostly bruises to her side. Because the incident occurred on private property no police report was taken.

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car image   Transfer Case problem of the 2004 Ford F-150 17
Failure Date: 08/01/2005

The vehicle accelerated when pressing on the brakes. Contacted the dealer, they did some work to it and said it was a diaphragm, and they fixed it. This worked for a while and then it started doing the same thing again. This was August 1, 2005. Noticed it made a groaning sound and shook. They replaced the transfer case, and it hasn't made the sound since then. When standing at stop it surged, gave a little jump/pulsated and touched the brakes. It happened intermittently.

car image   Transfer Case problem of the 2003 Ford F-150 18
Failure Date: 06/10/2005

I was driving down the road at 50-55 mph and my 4x wheel drive kicked on without me engaging it, then by itself again it turned off. The next night I was turning a corner and it did it again, it went on and off by itself. My boyfriend did not believe it and then an hour later he was driving and I did it again. I took it the dealer days later and they couldn't find out what it was . They said they tried to provoke it but they couldn't find out why and how it was happening.

car image   Transfer Case problem of the 2003 Ford F-150 19
Failure Date: 03/14/2005

While driving 55 mph the front hubs locked. As a result, the vehicle disengaged out of 4-wheel drive without warning.

car image   Transfer Case problem of the 2000 Ford F-150 20
Failure Date: 03/15/2004

Our truck jumps into 4 wheel drive by it self.

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car image   Transfer Case problem of the 2000 Ford F-150 21
Failure Date: 03/14/2004

I have a 200 Ford F-150 that goes into 4 wheel drive by itself could caus a major accident Ford repaired it after two attemps and almost one major accident and two towing bills and Ford does not fix any damage to the transfer case noting the gears could be stripped and wore down becase of this problem and 4x4 systems so owners are left with a large repair bill down the road on there four by four systems transfer case and joints seals and possible transmision damage.

car image   Transfer Case problem of the 2003 Ford F-150 22

The four-wheel drive would not operate properly. The vehicle was taken to a dealer that replaced the parts with parts from another vehicle of the same make, model, and model year. Those parts failed the same day of repair. Please provide any additional information.

car image   Transfer Case problem of the 2003 Ford F-150 23

At highway speed vehicle goes into low 4-wheel drive.