Intermittant knocking and loss of traction in 4WD

[M6F]

Hi, first time poster.

I have a '07 Ranger Sport 4wd and i live up a snowy mountain in BC so i have to use the 4wd often in the winter, however when i do a semi dangerous problem occours.

In 2wd the truck drives totally fine but when i put it in 4wd and am accelerating uphill there is an occasional knock from somewhere in the transmission which causes the rear wheels to briefly lose traction and slide out. This is a real problem in the snow, i nearly skidded off the road a couple of nights ago. It doesn't happen on the flat or when i'm pulling away, just accelerating uphill and sometimes coasting downhill. I'm at a loss as to what it might be. I'm going to try to take it to a garage next week but was hoping someone here might have an idea as to what it might be.

I already checked the UJ's and there doesn't seem to be any play in them.

 

[RonD]

Welcome to TRS

Manual or Automatic transmission?

Look on drivers door, back edge, for your Rangers Build Label, this is specific to this vehicle
At the bottom look for the code number under AXLE

Go here: https://www.therangerstation.com/tech_library/axle_codes.shtml

If you have an L/S(limited slip) rear axle then its time for new clutch packs in the differential, but this would have nothing to do with 2WD or 4WD setting in transfer case

As for 4WD part, it could be the shift motor is not moving the transfer case fully into 4H, or 4L

When you can, shift transfer case into 4high and turn off key
Get under the truck and remove the shift motor, 3 or 4 bolts
The triangle point of shift rod should be pointed exactly at 4H

Look at the pictures here: https://www.therangerstation.com/tech/rebuilding-a-ford-transfer-case-shift-motor/

picture 4 shows the shift rod pointed exactly at 2H(2WD), yours should be pointed at 4H
its possible the shift motor is not moving the shift rod fully into 4H
In picture 1 you can see the 3 torx screws holding down the 5 wire "cap", under that cap is the contact plate and contacts that "tells" the 4x4 controller when shift motor is in the correct position for 2H, 4H and 4L
But there are NO sensors in the transfer case to confirm that, lol

And that "cap" can be adjusted, turned a little, which would then turn shift rod farther one way or the other, to get shift rod pointed exactly at 4H, or 4L as needed

 

[M6F]

Welcome to TRS

Manual or Automatic transmission?

Look on drivers door, back edge, for your Rangers Build Label, this is specific to this vehicle
At the bottom look for the code number under AXLE

Go here: https://www.therangerstation.com/tech_library/axle_codes.shtml

If you have an L/S(limited slip) rear axle then its time for new clutch packs in the differential, but this would have nothing to do with 2WD or 4WD setting in transfer case

As for 4WD part, it could be the shift motor is not moving the transfer case fully into 4H, or 4L

When you can, shift transfer case into 4high and turn off key
Get under the truck and remove the shift motor, 3 or 4 bolts
The triangle point of shift rod should be pointed exactly at 4H

Look at the pictures here: https://www.therangerstation.com/tech/rebuilding-a-ford-transfer-case-shift-motor/

picture 4 shows the shift rod pointed exactly at 2H(2WD), yours should be pointed at 4H
its possible the shift motor is not moving the shift rod fully into 4H
In picture 1 you can see the 3 torx screws holding down the 5 wire "cap", under that cap is the contact plate and contacts that "tells" the 4x4 controller when shift motor is in the correct position for 2H, 4H and 4L
But there are NO sensors in the transfer case to confirm that, lol

And that "cap" can be adjusted, turned a little, which would then turn shift rod farther one way or the other, to get shift rod pointed exactly at 4H, or 4L as needed

It's a manual. Thanks for the info, i'm pretty sure it's not a limited slip axle, if i'm in 2wd the rear inside spins up too easily when pulling away on slippery surfaces, but i'll take a look anyway.

I'll see if i can gather up some tools to try rebuild the motor. Thanks!

 

[RonD]

Don't need to rebuild the shift motor, just check if its shifting transfer case into correct position

 

[pjtoledo]

something to note: the position of the pointer on the shaft is only an indication of what gear/mode the transfer case is supposed to be in.
it does not necessarily mean the mechanism inside the case actually & fully changed to the selected gear.


the shaft puts pressure on a spring, the spring turns a cam, the cam moves the shift fork(s), the forks move the collar(s) that engages the selected mode.

 

[M6F]

Got it, thanks

 

[pjtoledo]

check out the pics in post #15 for some "inside information"

Electronic Transfer Case Motor Diag | The Ranger Station

 

[M6F]

So i took the motor off and the shift arm was pointing slightly to the left of the 4H so i take it this isn't right. I tried loosening the cap to adjust the motor but all 3 screws were seized and very soft so i can't get them undone

 

[RonD]

It needs to be pointed right at 2H, 4H or 4L to be correct, so no not correct

If you can't get another one easily, drill out the 3 screws and replace with self tapping screws so you can make the adjustment if that's all you think it needs

Once that cap is off you can inspect the contact plate, maybe its corroded and causing the misalignment

Be sure to mark stuff as you remove it, or take lots of pictures as you go, lol

 

[M6F]

Figured i should update this. Tried a new motor as the old one was rusted out and not selecting 4H properly but it didn't make any difference. Talked to a transmission place in town and they said the rebuild cost would be in the thousands so they ordered a used, low mileage case from a wreckers for me and bench tested it to make sure it was all good. I swapped it out and it's all good again. Makes driving in the snow a lot less terrifying when you have 4wd. Thanks for the help

 

[DILLARD000]

Good that you've got it fixed. Curious; was this a 1354 TransferCase ?
No spec for Engine\Tranny\TransferCase... in your Profile\Signature\Post...
The rear diff spec should be on the DoorFrameLabel or DiffCoverTag.

 

[dvdswan]

Welcome to the site. Glad your issue got solved.

 

[M6F]

Good that you've got it fixed. Curious; was this a 1354 TransferCase ?
No spec for Engine\Tranny\TransferCase... in your Profile\Signature\Post...
The rear diff spec should be on the DoorFrameLabel or DiffCoverTag.

Yeah it was a BW1354