i got an 02 f-150 FX4 and the other day when i put it in 4 hi i heard a pop. the 4 wheel drive stopped workin. could it be solenoid? any ideas?

 

Is it manual 4x4 or electronic? It could be shift motor or numerous other things. Does truck still have 2w? You might want to try putting back in 4x4 again 2c what happens, but go slow, then put load to transfer case 2c if it pops. It might not be fully engaged ie. shift fork hanging up and when you hit gas gears being not fully aligned pop out of mess. This could be motor on transfer case, forks etc. Eliminate the obvious 1st, then let me know.

gauge7

 

ya its electric 4 wheel drive. im gunna try and do some trouble shootin next weekend and will let u know if i find any thang or if i have any questions

 

ok i did some trouble shootin and the transfer case, both solinods and actuator work properly. im actually still not sure about the shifter fork movement. i read somewhere the it is supose to move a total of 2 inches in or out of the actuator? mine is only moving about 1 inch in or out.

 

remove shift motor and try turning pivot manually with pliers to c if u can fully engage shift fork. it's possible fork is jamming on rail, broken or badly worn.

 

the shift motor on the transfer case?

 

yes, motor is bolted to transfer case, it selects your 4x4 ranges, if u remove it u can get a buddy to select 4H or 4low inside truck ...key on. u with motor in hand and harness still plugged in will c if it is turning drive on motor. if it is then move rod in transfer case 2 different positions 2 c if u can select appropriate range.use wire with alligator clips on each end 2 ground motor 2 case just in case harness plug doesn't. when moving rod manually u will feel and hear fork slide gear into place.

 

ok thanks will try that out this weekend and let u know.

 

i took the shift motor out and had someone switch it back and forth in 4hi and 2hi. from what i saw it looks like the shift motor isnt rotating enough to lock the transfer case in, so i tryed turning the rod on the transfer case manually to 4hi marking on the case to see if it would lock in. i drove it down the road and didnt seam like it locked in but im not sure if i turned the rod far enough. should it like click in to place or fall in or somethin cuz it didnt even feel like it when into 4hi when i turned it manually, it just stopped. not sure what to do next, but im pretty sure i need a new shift motor?

 

put truck on stands (all 4 wheels) move rod to position for 4H or 4L and drive 2c if all wheels r turning. move rod full travel to lock in. if front wheels r not turning then problem is in transfer case. either get a used 1 from wrecker or take yours out and pull apart. u should mark all parts with a paint if not a mechanic so u'll know how 2 reassemble. There should b a tin tag held on by one of the case bolts...the letters and numbers on it will help u in getting the proper replacement or parts from a dealer. The dealer will ask u 4 that tag.Keep me informed.