4Lo popping sounds

[The 2002 Danger Ranger]

Whenever I shift to 4Lo and put the truck under a load there is a loud popping sound. The front tires seem to stop spinning when it pops then start spinning again, seems like they momentarily disengage. At first it would only do it when I had to romp on it, then it got worse (every time i use 4Lo), now the transfer case drops to neutral after a few pops. Plus its starting to do it in 4Hi. Also, I have the manual shifting transfer.
Any ideas?

 

[90jurassic2]

I had this same problem I swapped in manual hubs. Don't know if it worked or not. It could be a worn ring gear though. That's what my buddy was telling me.

 

[UrbanRedneckKid]

Doubt its in the case, as weak as the front end parts are on ifs trucks.

Sounds like a hub, or maybe a CV joint, possibly in one of the axles or driveshaft.

But who knows... Internet diagnosis is tough due to wording and interpretation of the issue.

Sent from my PG86100 using Tapatalk 2

 

[gw33gp]

I had something similar to his happen when my truck was still under warranty. I noticed it in 4-hi but don't know if it did it in 4-low. The dealer replaced the transfer case drive chain and it still did it. The dealer could not figure out the problem but they were not very familiar with the transfer case anyway. They ended up installing a new transfer case at my request and the problem was solved. Unfortunately, I never did find out the cause of the problem because Ford took the old transfer case due to warranty replacement.

I had a problem with the transfer case shift lever adjustment after they installed the new transfer case. They told me they could not find the instructions for adjustment. I had a Ford repair manual and copied the instructions for the technician. It came back to me even worse than is was the first time. I ended up adjusting it myself and haven't had a problem with it since then.

 

[Redneck_Ranger]

I had to replace mine because the chains and sprockets stripped out no matter where I was. It started out gradually at first then came to the point where I had no 4x4 at all whether I was in high or low range... That's what it sounds like to me, especially if your wheels don't turn when it happens.

 

[The 2002 Danger Ranger]

Thanks for all the help, I think that I am going to rebuild my T-case and hopefully that fixes my problem. If not then I guess I'll be asking around again for more help.

Has anyone rebuilt this case before? How difficult is it to do and are there any special tools that I might need?

Thanks again for the help.