Howdy all,

I have a problem with my transfer case. When I first bought the truck a few years ago, it had the snap ring broke on the rear tail shaft which was an easy fix. I noticed toward the end of this last winter that when I put it in 4wd, it has a popping noise coming from the transfer case. The 4 wheel works but when you put it under any load it pops.

What should I look for, and if I need to, what all is involved with taking out the transfer case? I've been an equipment mechanic my entire life and have rebuilt many car engines and automatic transmissions so I feel comfortable doing this, but i've never been in a transfer case other than to replace the snap ring mentioned above.

One other thing, When I put it in 4wd, it seems to take a good while to engage. The light blinks and seems to take about a minute before it stays on, sometimes a little less and then sometimes I need to go back to 2 wheel and then push 4 wheel again. Could both of these problems be related or do I maybe have a solenoid on the front differential that might need replaced?

This has the 7.4 if it makes any difference.

Thanks in advance for any suggestions.

 

Nobody ever had this problem before?