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2021 Tremor Transfer case issues

Coletrickle

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Cole
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2021 Ford F-150 Tremor
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Has anyone experienced any issues with their transfer case in the 2021 tremors???

My 2021 Tremor is at the dealership right now for the 2nd time for this same issue. Noise was only there in 4A or 4H and under a load/acceleration. I can feel a rumbling in the floorboard and gas pedal when it is doing it. First time it was in the dealer they rebuilt the front diff and replaced both front axels. They told me the diff fluid was silver then. This was less than 4,000 miles ago that the work was done. The noise was never gone but I took it back and decided to drive it anyways. I may be used 4A a couple times since to see if the noise was there in the last 7 months (so 2H 99% of the time) and I finally took it back into the dealer to have them check it again. They called me today and said the front diff needs to be rebuilt again and the fluid was silver. They have no idea what is causing this. They told me that the issue is from my front leveling kit is putting too much strain on the front diff. The Level kit is the Eibach springs and struts level kit for the Tremor specifically and running 285/75R18 on stock wheels. I put the level and tires on it at 7500 miles and didn't have the issue until about 23,000 miles or so. I'm at a loss right now and frustrated that they said that the leveling kit is the issue to my problem, but they can't even tell me what the actual problem or fix is.

Any input would be great.
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tide1996

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I don’t think your level kit is the root cause. The fact that it only happens in 4A/4H points more to the transfer case or driveline binding, not just the front diff. If the angles from the kit were that bad, you’d normally see CV/axle failures first, not two destroyed diffs.

I’d push the dealer to check the transfer case clutch/actuator and driveshaft angles,
 
 







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