Transfer case failure.

[DALOLA]

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 .

Was there no discussion about what they found? That the new unit was test driven & confirmed ok? They just tossed you the keys, and off you went? Makes we wonder what they actually did...

These days, you have to verify EVERYTHING.

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[Nacho23]

Was there no discussion about what they found? That the new unit was test driven & confirmed ok? They just tossed you the keys, and off you went? Makes we wonder what they actually did...

These days, you have to verify EVERYTHING.

Yeah, I mean they said it was an internal transfer case failure. They replaced it and supposedly test drove and verified the repair. I drove it home and parked it at work until after the storm and that’s when it happened all over again.

 

[Snacktime]

If you have 3.73 gears you need to check the front differential. Most likely the part time shift motor. Also could be the the fact that the Drivers side cv axle has the potential to seize to the carrier inside the front differential.

 

[crenca]

Yeah, I mean they said it was an internal transfer case failure. They replaced it and supposedly test drove and verified the repair. I drove it home and parked it at work until after the storm and that’s when it happened all over again.

That is vague to be honest. Do you have the paper work from the dealer, and if so can you scan it and post it here?

Regardless, you need to have a serious discussion with the service manager and get the details as to what exactly they replaced and why. It's all speculation here.

 

[Nacho23]

That is vague to be honest. Do you have the paper work from the dealer, and if so can you scan it and post it here?

Regardless, you need to have a serious discussion with the service manager and get the details as to what exactly they replaced and why. It's all speculation here.

All I got for an explanation was that they verified the fault, pin tested the tc and got no response, pulled the tc drain plug and noticed “chunky” fluid draining out. Trust me that many questions have been asked, and have yet to be answered. I can send you the paperwork whenever I am back at the house, but the most in depth it gets is the customer comments section.

 

[jtgensler]

So was there a physical failure of the T-case? Or just an electronic won't engage failure.
If it's just electronic, check the battery SOC & make sure they update the module.
Not sure about the part time, as mine has the advanced case, but I was having issue with a warning light popping up that would reset when I cycled power & I had low battery state of charge that was combining with not receiving an update to the 4wd module. Had it updated at the dealer, combined with topping the battery off & no issues since.

 

[Brian_B]

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.

Part of that is "normal" in snow/sand and doesn't necessarily mean anything is wrong.

If the ABS detects "excessive" wheel slippage, it will throw a fault code, thinking you may have a broke axle or something. But in Snow/Ice/Sand, wheel slippage is entirely normal.

There was a TSB about it a while back for this detection being a bit too sensitive.

Having the wrench does disable GOAT modes, and maybe 4Hi (along with some of the automated things like collision detection, cruise control, etc), but should still be able to go into 4Lo. I think if you shut off the vehicle and turn it back on it should clear (the code will remain stored but won't pop up wrench until it detects excessive slip again).... if this was the issue.

As @Snacktime alluded to, I've also seen the exact same thing with a failed FAD on the m190 front diff, and I've seen it when a Wheel Speed Sensor breaks. And it would do it if you actually broke an axle or something.

 

[crenca]

All I got for an explanation was that they verified the fault, pin tested the tc and got no response, pulled the tc drain plug and noticed “chunky” fluid draining out.

So was there a physical failure of the T-case? Or just an electronic won't engage failure.

@Nacho23, as you can see from the limited information you have many of us are speculating the fault lies elsewhere then the TC itself (and "electronic" fault upstream). Even the "chunky fluid" might just be a dealership taking the easy way by covering the warranty work with Ford corporate by the claim (which may be true to some degree). OR, they may have found a serious defective TC but you have another issue as well.

If it was me (fully realizing not everyone is like me ) I would:

1) Visit the service manager and firmly ask for specifics
2) Get a second opinion from a local independent shop before letting the dealer wrench on it anymore as sometimes "free" turns out to be an real expense in time, hassle, and $.

 

[Nacho23]

@Nacho23, as you can see from the limited information you have many of us are speculating the fault lies elsewhere then the TC itself (and "electronic" fault upstream). Even the "chunky fluid" might just be a dealership taking the easy way by covering the warranty work with Ford corporate by the claim (which may be true to some degree). OR, they may have found a serious defective TC but you have another issue as well.

If it was me (fully realizing not everyone is like me ) I would:

1) Visit the service manager and firmly ask for specifics
2) Get a second opinion from a local independent shop before letting the dealer wrench on it anymore as sometimes "free" turns out to be an real expense in time, hassle, and $.

Agreed, I will see what they come back with and go from there. Just incredibly frustrating.

 

[Nacho23]

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…

Update: after replacing the transfer case, the powertrain/awd fault was still coming on. They brought in a field engineer from Ford who diagnosed a failing transfer case module, they replaced that and it's been working great since. Now that it is fixed, I doubt that it has been fully engaging for a long time. I don't remember it ever feeling this strong with 4h engaged. fingers crossed this takes care of it.

 

[BigBirdStewart]

Hmm... I'm waiting for anew transfer case after several weeks of Powertrain faults. They replaced the module - Still had faults - and then an engineer from SLC, UT said I needed a new transfer case.... Which is on infinite backorder.
Fast forward a few weeks - No fault codes for several weeks, shifts fine.
Is the module in the case? Just wondering

 

[Nacho23]

Hmm... I'm waiting for anew transfer case after several weeks of Powertrain faults. They replaced the module - Still had faults - and then an engineer from SLC, UT said I needed a new transfer case.... Which is on infinite backorder.
Fast forward a few weeks - No fault codes for several weeks, shifts fine.
Is the module in the case? Just wondering

Good question, I thought it was inside the engine compartment above the passenger wheel well. Not 100% though. Good luck! So far mine has been holding strong since the TC and module, but I haven’t really been able to work the 4x4 enough to get my confidence back with it.

 

[VirginiaHeritage]

For those that have had transfer cases replaced, be sure they reconnected the breather tube and clamped it. Near the top of the t-case is a hose barb and there should be a black tube clamped on there. I had my advanced T-case replaced at 12k due to a noise and they forgot to reconnect it.

I never had any functional problems or codes but the Bronco had a low speed rotational hmmm-hmmm-hmmm sound most apparent at 9-12mph that one dealer thought was wheel bearing (and replaced it) even though I never felt any excess heat in the wheel. That didn’t fix it. After I noticed some fluid got spewed from the back of the transfer case where the drive shaft connects, I took it to another dealer who replaced the t-case under warranty. The noise went away. I had to go back later when I eventually realized they forgot to connect the breather tube and fluid was dripping from the hose barb down a wire harness. I told them to 1) connect the hose and 2) drain and replace the t-case fluid at no charge and they did.

Now I have a recall linked to that repair because the transfer case and tranny may not have been aligned correctly and the splines can get worn leading to very bad things. No issues in the 10k since it was done though so mine might be fine. When parts are available (supposedly in early May) the dealer will contact me to make an appointment for inspection and repair if needed. I’m assuming they need to remove the t-case again for the inspection so I will be rolling under there the minute I get home to be sure it all looks good.

This is what you don’t want to see after a replacement:

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