Transfer case failure.

[Nacho23]

Hey everyone.
To start, I have a 2023 non-sas, 2.7, 4-door Outer banks. The Bronco is currently in the shop with a failed transfer case. I have been doing some searches to see if anyone else has had similar issues but didn’t come up with much. Anyone out there with a failed transfer case, and possible causes?
My issue was really benign. I have probably used 4wd less than five times, and only when snow was deep enough to get me stuck. I’m a relatively ocd guy and haven’t shifted on the fly. The problem began a month ago: roads covered in deep snow, city driving, engaged 4h at a stop light and kept it engaged for about a mile (straight line). And disengaged when the wrench and powertrain fault illuminated on the dash. I got home, plugged in my scan tool, found no codes stored, and light reset itself when cycling the ignition. The dealer is repairing under warranty and have zero complaints about that. I’m just trying to understand how fragile a transfer case is, and how this one could have failed.
So I guess I’m just looking to see if anyone has had issues with their transfer case with light use of the 4wd system? And what are some causes of an internal failure? I’ll update with more info if I get any more insight from my dealer.

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[Strizzo]

which transfer case do you have? there has been some discussion as to whether the advanced tcase has an actual locked center diff in 4-low or if it just applies the clutches like the jeep 392 transfer case does, which has led to some failures rendering the rig 2wd only.

 

[Nacho23]

which transfer case do you have? there has been some discussion as to whether the advanced tcase has an actual locked center diff in 4-low or if it just applies the clutches like the jeep 392 transfer case does, which has led to some failures rendering the rig 2wd only.

I have the part time transfer case, not the advanced. (I thought I’d escape possible issues by going this route lol).

 

[Zero Options]

It is definitely not that fragile; there must be some kind of defect in yours. I have a friend with a base model that might have accidentally engaged 4H when he meant to put it in sport mode on dry roads and didn’t realize it until the tires chirped in a parking lot. I, I mean he has also played around off road in 4L and driven in snow in 4H and everything as been fine for a couple of years.

 

[Rob_Broncowski]

Check out this thread.

https://www.bronco6g.com/forum/threads/front-differential-failure-club.128760/

 

[DALOLA]

Could also be an electronic component to it, causing a failure. Best to wait, see what the dealer finds when they pull it out. By all accounts, these TC's seem pretty robust, both versions, so I'd say you are just unlucky.

 

[Nacho23]

Thanks everyone for the info. I just heard from the dealer that’s it’s ready for pickup. The tech said he did a pin test with zero response, then pulled the drain plug and the fluid had fragments in it. Sounds like that’s as in depth as they will get with causes. Thankful for the warranty!

 

[userdude]

Not the transfer case, but I had the front axle replaced because the front diff was grinding. The proximate cause on the tech notes was one of the four mounting bolts was missing.

 

[Nacho23]

It is definitely not that fragile; there must be some kind of defect in yours. I have a friend with a base model that might have accidentally engaged 4H when he meant to put it in sport mode on dry roads and didn’t realize it until the tires chirped in a parking lot. I, I mean he has also played around off road in 4L and driven in snow in 4H and everything as been fine for a couple of years.

Good to know, I couldn’t imagine that anything I’ve used it for would cause a failure

 

[MC1313]

I just had mine replaced. First time I engaged it on the snow light started flashing and service soon light. They had to replace the unit due to an electrical problem in the unit. Took them 3 days which was quick considering they had to order the part. 12,500 miles on mine

 

[Nacho23]

UPDATE: picked up the bronco last sat am after they replaced the transfer case, 4wd/powertrain fault again by Monday evening. Put it into 4h driving through snowy residential streets is apparently not enjoyable for this machine .

 

[crzyhawk]

I tend to try and avoid 4wd on pavement unless absolutely necessary. Different story if I'd gotten 4a, but here we are.

 

[Nacho23]

I tend to try and avoid 4wd on pavement unless absolutely necessary. Different story if I'd gotten 4a, but here we are.

Same, but this wasn’t pavement, foot and half of snow after the blizzard. And less than 2 minutes of driving before the fault came on.

 

[23OBX2.7]

UPDATE: picked up the bronco last sat am after they replaced the transfer case, 4wd/powertrain fault again by Monday evening. Put it into 4h driving through snowy residential streets is apparently not enjoyable for this machine .

I use 4H with rear locker engaged often on snowey streets with no issues. Something else is wrong.

This is a very stout drivetrain could even use 4H on fry pavement ...the tires suffer taking up all the bindinfg stress.

 

[SierraBronco]

I use 4H with rear locker engaged often on snowey streets with no issues. Something else is wrong.

This is a very stout drivetrain could even use 4H on fry pavement ...the tires suffer taking up all the bindinfg stress.

Yeah something is definitely up. People are using these locked in to 4L while on slickrock AKA super grippy sandpaper and not having issues like this.

I wonder if it’s just partially engaging…

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