Transfer case motor replaced today and won't go into 4 wheel drive at all
SOURCE: Grinding in and out of 4 wheel drive
You say 'new' truck, 09? or new used? I have had 3 Fords, 3 w/ manual trans. case, if you go into 4x4 Low range, you must come to a complete stop before shifting the trans. case to 4x4 mode, and I always put trans (automatic) in neutral before slipping into 4x4, it engages smoothly, no grinding. 4x4 high range can be put in while moving, but I would let off the gas pedal, shift to 4x4 high range, then resume accelerating. If there is any grinding going on doing it as above, something isn't right. Check the trans. case fluid level also, to make sure that's not an issue.
SOURCE: transfer case is making noise. can i still drive
NO. even tho its not in 4wd parts inside still rotate, there is probably no oil in it, they commonly leak with high milage, have it looked at before it comes apart or locks up
SOURCE: 2002 dodge Dakota stuck I'n 4 wheel drive so u
The 4x4 is controlled by vacuum. There is a vacuum switch on the top of your transfer case that control the vacuum to the front axle shift motor. The shift motor has 2 ports, when vacuum is applied to one side the shift motor moves the fork one way and when vacuum is applied to the other side, the fork moves the other way.
The first thing I would do is verify the hoses at the transmission cross member are hooked up. Then I would remove the 4 bolts from the shift motor and remove the motor and start the engine and shift in and out of 4x4 waiting 10 seconds before each shift and see if the fork moves.
If it doesn't you will need to check the vacuum connector on top of the transfer case and make sure it is fully attached, if it is, you will need to remove the vacuum connector and check to see if you have engine vacuum on one port(around 15" vacuum). The ports are as follows - one port goes to engine vacuum, one port goes to a vent and the other two go to your shift motor. The hoses that go to the shift motor are bad for getting plugged, so you should use compressed air and see if they are clear.
If everything checks out, you will have to remove the switch on the transfer case and operate it by hand while the engine is running and see if the plunger moves in and out. Sometimes the plungers will stick in!
A vacuum gauge and pump are needed to check the motor and switch. If you don't have one, you might need to borrow one and put a vacuum on the shift motor and see if it holds vacuum. Once you put a vacuum on the shift motor the fork should move and then should pump down and hold a vacuum, if it doesn't hold vacuum, you will need a shift motor.
This is alot of info, but there are many possibilities for this not working and you will have to check all these things to diagnose this.
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