Transfer Case Problems of Ford F-250

The contact owns a 2024 Ford F-250. The contact stated that upon routine service, it was noticed that the vehicle had 2 separate 4-wheel drive hubs, a left driver-side automatic hub and a right passenger-side dummy hub. The contact's concern was that the manufacturer's design could reduce fuel efficiency. The local dealer was contacted. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 18,000. The VIN was not available.

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Traveling on I-15 freeway in southern California, going 70 mph on cruise. Head a loud "bang", pulled over and saw damage to underside of vehicle and fluids leaking. Transfer case appeared to be split open. Towed to mojave Ford dealership in barstow California, where repairs were made. Description of findings is attached below. Problem seems to have originated in the 4wd system. Truck was in 2wd in the cab, however vacuum hubs were in 4wd. Mechanic stated that this is a problem with Ford trucks. No recall on file. Post repair, the truck still stays in 4wd when reverting to 2wd from the cab. Operator is required to manually put hubs into 2wd.

See all problems of the 2010 Ford F-250 🔎.

At approximately 3 pm on Saturday, June 2, 2018, my 2008 F-250 sd 4wd truck experienced an abrupt catastrophic failure of the transfer case. The incident occurred on a busy interstate corridor while I was traveling at approximately 70 mph while in 2wd mode. Immediately prior to the incident, a dull rumble could be heard, which rapidly amplified to a loud roar. I removed my foot from the accelerator pedal and was almost immediately jolted by a thunderous explosion that emanated from underneath the vehicle. The entire truck shook violently as I pulled over onto the highway shoulder. As the truck lurched forward hesitantly, a cloud of thick smoke billowed out from below the truck near the front doors. Upon exiting the vehicle, I noticed that transmission fluid was pouring out the transfer case, whose exterior wall had literally been ripped apart. Large gear components from the transfer case were strewn along the highway shoulder. The explosion within the transfer case caused several internal parts to be ejected with significant force and velocity. The sizable indentations and large scrapes inflicted upon the exhaust system and the passenger floor pan, respectively, are a conspicuous testament to the forceful discharge of these various components parts from inside the transfer case. The substantial energy contained in this explosion necessarily implies that tremendous pressure was building up inside the transfer case. Furthermore, the thick, acrid smoke released following the explosion is also indicative that the transfer case was subject to appreciable heat generation. Fortunately, and rather incredibly, no injuries nor crashes were sustained when the transfer case precipitously burst. Despite the absence of collateral damage or casualties, the severity and magnitude of this inexplicable equipment failure warrant documentation as this is a critical part malfunction.

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2004 Ford f250. Consumer states faulty icp sensor or faulty egr valve the reverse planet gear in the transmission was replaced. The egr valve replaced three times, the egr cooler, oil cooler were all replaced. The r&r turbo intake was replaced twice, the turbo inner cooler, wiring harness on the engine, transfer case, ficm module were replaced. The alternator and battery were replaced three times, the valve assembly, high pressure and regular oil pumps were replaced and a new egr shield was installed. The vehicle also stalled while driving down the interstate.

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The contact owns a 2008 Ford F-250. While driving 10 mph on icy road conditions, the contact noticed that his four wheel drive would not engage on two different occasions. The risk of a crash was increased. The dealer stated that the vacuum hose for the four wheel drive was manufactured too short. Therefore, when making sharp turns, the component would easily fail. The hose has been replaced twice at the cost of $56 per hose. The failure mileage was 40,000 and current mileage was 44,000. Updated 3/24/09 updated 03/27/09.

Transfer case on 4x4 F-250 sd defects locks up wheels traveling hwy. (4 wheel drive not engaged). Vehicle skids hard left causing rollover. State hwy patrol investigation concludes equipment failure to be cause of accident. Vehicle remains unrepaired for further investigation and documentation.

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: the contact stated twice the vehicle jumped into four-wheel drive on its own causing the vehicle to lock up. When this occurred, the steering was very difficult to put into gear. The first time this occurred, the dealership installed a vacuum pump assembly. The second time, the dealership determined the motor on the transfer case needed to be replaced.

On December 4, 2004, I took my truck on about a 600 mile trip. During the trip I tried the cruise control, which worked about 5 months earlier & found it to be nonfunctional. The next day, I found myself in a position that required engaging the four-wheel drive, however it would not engage. I parked the truck that evening & had not touched it in the following month and a half. On December 10, 2004 my wife canceled the insurance since my plan was to leave it parked until spring or I could afford to get it fixed. Then on January 26, 2005 @ 05:00 am, my wife woke me up saying that my truck had just exploded. I went outside & saw the fire in the engine compartment. At that time the main concentration of the fire was on the driver?s side. I notified Ford, to which their reply was sorry for your inconvenience but there are no recalls on your vehicle & it is also out of warranty.

See all problems of the 1997 Ford F-250 🔎.

Ford F-250 4 wheel drive. 4 wheel drive system is faulty. Seals on system go bad and cause lack of pressure to turn hubs to 4 wheel drive mode. Very expensive to fix. Complaints from many people I know including Ford mechanics stating the system is of very poor design.

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Four wheel drive wont engage at times never know if its lock in even when indicator light says your in four wheel drive . Dealer replaced hub but it still does it. Mechanic reported that his bay partners truck does the same thing. They now tell me they believe its a cold weather problem and that they cant diagnose it any futher as temps are to warm . Its now been at the dealership (northhampton Ford in mass. ) for atotal of 12 days for this problem. I have all contacted my district attornies office regarding this matter. Previous to this Ford did over $1000 in parts alone warrenty work . At times I have not been able to make it home in three inches snow.

Truck was at a stopped position and I noticed that the locking hubs would not stay engaged. There was a very loud grinding noise. I have not been able to use the 4wd since the incident.

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Consumer states while stuck in snow bank with four wheel drive on the four wheel drive would not engage. Consumer notice grinding noise. Dealer has been contacted please provide further information. Ts.