Ford Super Duty (1999-2016) :: 2001 F250 - 4x4 Won't Engage


Apr 17, 2013

My truck: 2001 F250 V8 Triton Automatic 4x4

Problem: 4x4 won't engage

Symptoms: No dash lights....nothing happens when I turn the 4x4 switch. When I start the truck I hear what sounds like a motor (transfer case motor maybe?) trying to switch (even though my dash switch is on 2WD)... It tries three times and stops.

What I've done: Checked fuses ...they appear ok to me

I don't have a maintenance manual yet ...

The 4x4 used to work up until about 2 weeks ago. Started having a hard time getting it to go into (and out of) 4x4 and then it just stopped all together.

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Ford Super Duty (1999-2016) :: 2004 F250 V10 - 4x4 Will Not Engage

4x4 will not engage. 4x4 light on dash does not come on. Can not hear motor switching into 4x4. Check fuses under dash all looked good.

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About a month ago I bought a 2004 F-250 160xxx from a reputable Ford dealer here in town. The dealer performed a safety and emissions inspection, and spent about a grand on other repairs, as a condition of my purchase. Today I had it in the shop for an instrument cluster issue (at a different Ford dealer, closer to my house), and was told the vacuum lines were all messed up. Their write up is below:

"Check 4x4 operation. Transfer case shifts to 4x4 and 4x4 low. Front hubs do not engage automatically. Check vacuum at the hubs. No vacuum. Check the vacuum at the solenoid. No vacuum. Perform visual of the engine vacuum lines. There is no vacuum to the reservoir. Vacuum line is routed wrong from the fuel pressure regulator to the vapor management valve. There is other vacuum concerns. All of the vacuum line routing needs to be inspected and corrected."

The service rep told me it is questionable whether the 4x4 ever worked, although during the few weeks I've owned it, I could hear gears or other mechanical parts making noise which seemed to me to be in response to me turning the 4x4 electronic switch. She also said there was a vacuum line dangling loose with a screw in the end of it.

Before I contact the dealer where I bought the truck, I am planning my going-in position. But I wanted to get a sense of a) how serious of a problem this might be? and b) how reasonable it is that the dealer didn't catch this issue before I bought the truck while they were in their fixing other things?

The dealer who sold me the truck made it very clear that the sale was as-is, and I took it to my mechanic prior to purchase, though unfortunately he only had time for a cursory look at the engine. Obviously he didn't look closely enough to find this issue.

I'm not sure if I should ask the dealer who sold it to me to fix it, or ask them to allow me to return it, or sell it back to them, or if I should eat the cost of fixing it. How wrong would it be to try to trade it in for something else?

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Took it to a shop and they drained the system and recharged it and they couldn't find anything wrong with it. Well, it's still doing it. We were starting to thing maybe it was an electrical issue with the cold/hot switch on the dash until a recently noticed a pattern. If it had gone hot and I got heavy on the accelerator (revving above 2500 RPM), it would get cold and keep blowing cold for 3-5 minutes. So the trick to staying cool as of now is just to hammer down every few minutes.

I read the HVAC FAQs, and it seems like the issue maybe with a slipping compressor clutch. Sound right? Also if that's the issue, it says the solution is: Excessive A/C clutch gap due to clutch wear. Usually, the problem can be resolved by removing a shim from the clutch to bring the gap back into the desired .014-.030 gap. What exactly do I have to do? Where and what are these shims?

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