Won’t move- stuck in 4L

[Liquid Lifestyle]

Where is that? Looks like it’s on the frame? I don’t recall seeing one like that. Crazy how something so integral is just so vulnerable. Good for you though, nice getting your truck back!

It is on the passenger side outside frame rail. I didn't see it on the trail because every time I climbed under to inspect the underside I came from the drivers side. when I was cleaning it I came from the passenger side. You can see in the picture it actually pulled out of the clip it has on that side.

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[Liquid Lifestyle]

Sounds like we need to make a shield for this plug!

I would buy one in a heartbeat. trying to figure out how best to shield it, at least from a wayward branch while trail riding

 

[Merc4x4]

1/2 round / U steel cable guard?
flanged, or separate holders
might have to drill, or maybe there are some existing holes.
https://www.hubbell.com/hubbellpowe...uction-Hardware/Cable-Guards-Straps/c/2666699

or, maybe it can be routed above and protected by a frame mounted slider.

 

[Fumey]

Well, transfer case chewed up. Trans tech says I was driving too fast, too long on high traction surface. My fault. Not covered. $4k.
Thing is, I’ve never driven in 4L outside of that off-road park (Holly Oaks for the local readers if you’re familiar). Never driven faster than 15-20mph. Trans tech says that’s too fast. Basically gave me a lecture about not using 4L. Went in circles with Ford customer service, the rep was using scripted answers, relying on this technicians diagnosis only.

 

[Headsong]

Well, transfer case chewed up. Trans tech says I was driving too fast, too long on high traction surface. My fault. Not covered. $4k.
Thing is, I’ve never driven in 4L outside of that off-road park (Holly Oaks for the local readers if you’re familiar). Never driven faster than 15-18mph. Trans tech says that’s too fast. Basically gave me a lecture about not using 4L. Went in circles with Ford customer service, the rep was using scripted answers, relying on this technicians diagnosis only.

This is total BS....an off-road truck should be ok off-road, duh!

 

[mpeugeot]

Well, transfer case chewed up. Trans tech says I was driving too fast, too long on high traction surface. My fault. Not covered. $4k.
Thing is, I’ve never driven in 4L outside of that off-road park (Holly Oaks for the local readers if you’re familiar). Never driven faster than 15-20mph. Trans tech says that’s too fast. Basically gave me a lecture about not using 4L. Went in circles with Ford customer service, the rep was using scripted answers, relying on this technicians diagnosis only.

Did anyone bother to look at the hardness of the gears. Bad heat treatment of the metal could have caused this. FWIW, I have done over 40mph (on grass and sand) in 4L in Baja mode.

This looks like a metallurgy failure.

If the metallurgy (and heat treatment) wasn't examined, that's the equivalent of mechanical malpractice.

 

[BigFootie]

Did anyone bother to look at the hardness of the gears. Bad heat treatment of the metal could have caused this. FWIW, I have done over 40mph (on grass and sand) in 4L in Baja mode.

This looks like a metallurgy failure.

If the metallurgy (and heat treatment) wasn't examined, that's the equivalent of mechanical malpractice.

You would expect a bunch then as this process is done in batches and not one at a time.

 

[da_jokker]

If this happened to me, the Bronco and Ford would be history and I'd go back to better built off road proven vehicles.

 

[Merc4x4]

Do you use Slippery mode? That is not meant for on-road if you don't have the auto x-fer case. It uses 4H. At least that's what I've read on the forum here.
I can see a lot of carnage in the future with a mode named Slippery and graphics that look like rain for drivers without the auto x-fer case.

 

[mpeugeot]

You would expect a bunch then as this process is done in batches and not one at a time.

Yes, but as the valve situation suggests, parts on the edge may or may not fail.

Most Broncos have extremely little time in 4L, if any at all, so we may not see batches for quite a while.

Also, those without the advanced 4x4 transfer case are less likely to be taken off road generally. Further making data analysis challenging for us mere peasants.

 

[Fumey]

Did anyone bother to look at the hardness of the gears. Bad heat treatment of the metal could have caused this. FWIW, I have done over 40mph (on grass and sand) in 4L in Baja mode.

This looks like a metallurgy failure.

If the metallurgy (and heat treatment) wasn't examined, that's the equivalent of mechanical malpractice.

I mentioned that to the service advisor and I’ve also requested a production tech to take a look. It also probably would’ve been beneficial to see it before it was completely disassembled. Right now all the components are sitting in the case like a salad in a bowl.

 

[Snacktime]

Need some pictures of the rear drive shaft. Also some more underbody photos. I got a feeling you hit a drive line on something and damaged the alignment of transfer case gears. Or you ended up damaging the case while moving it since it wasn't in gear/neutral.

Welcome to the pay to play group. Car-part has a used one for $750.

 

[BigFootie]

Yes, but as the valve situation suggests, parts on the edge may or may not fail.

Most Broncos have extremely little time in 4L, if any at all, so we may not see batches for quite a while.

Also, those without the advanced 4x4 transfer case are less likely to be taken off road generally. Further making data analysis challenging for us mere peasants.

Agreed, but I’d still expect a few more considering at least what if seen of people taking them off road plus what I would expect as many new to the vehicle driving it in transfer case ranges not as designed. Not like the old days of having to get out to lock in the hubs.

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