Three problems related to transfer case have been reported for the 2015 Ford F-150. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2015 Ford F-150 based on all problems reported for the 2015 F-150.
While driving the vehicle a grinding noise emanated from somewhere near the front wheels. The was also the feeling of a shutter or a shake from the same area. This was felt in the steering wheel. After taking it to the Ford dealer, we were told they took a fluid sample from the transfer case and found it contaminated with metal. At 44,576 miles, we had to replace the transfer case.
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.
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.