Two problems related to transfer case have been reported for the 2009 Ford F-150. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2009 Ford F-150 based on all problems reported for the 2009 F-150.
The rear drive shaft between transfer case and rear differential is held by a drive shaft bracket/bearing where the top of it is welded to the frame cross member. During stop and go traffic the poorly welded bracket came loose. As you can see from the picture the weld was poorly done and had no penetration into the metal. The metal was not torn at all and broke completely clean off which dictate a very poor job on the weld itself. To make matters worse this part is basically a dual sharp blades at the weld break, connected to the drive shaft at fast rpms would take little to no time to puncture and ignite the near by fuel tank. As I was traveling at slow speeds I was able to stop the vehicle right away. If this break occurred at highway speeds I feel that it would have easily punctured the fuel tank and ignited the fuel causing catastrophic fire and probable explosion that could cause injury or death.
Truck stalled and lost transmission power in the middle of busy highway. Waited 20min on shoulder and truck started and ran fine. This has happened periodically over the last year with no error codes found during diagnostics related. Now happing more frequent and yesterday the truck stalled again and now will not start. Researched and found a class action lawsuit about Ford pcm/tcm failures which described my symptoms perfectly. Next issue is at 55mph the truck tried to go into 4-low, which shut the truck down on the high way and almost went off the road. Error code found during diagnostics was the "communication to transfer case shift motor".