Sounds like the current work truck is just a lemon with lots of issues.

If a truck is driven 200,000 miles it would be extremely rare to see 2000 miles of use in 4X4. Even if it had 20,000 of those miles in 4X4 that isn't enough use to wear out any of the 4X4 components. When people have 4X4 issues it is almost always operator error. People engage 4X4 when they shouldn't, or they let it sit for months or years without ever using 4X4. Both approaches will damage parts. The problem with both is that the damage doesn't show up at 1st. It is always later, often much later and usually when you really need to be in 4X4 when you find it no longer works.

Properly maintaining the 4X4 system is just as important as changing the oil. It should NEVER be engaged on a surface with a hard surface and good traction. But it should be engaged on a regular basis and driven a few miles on a dirt or gravel road. About 10 miles/month is recommended. I don't always get into 4X4 each and every month, and some months I may only get in 2-3 miles. But I won't let it go over 2 months without engaging 4X4 and make it a point to get in a good long drive of at least 20-30 miles occasionally. I also engage lo range and lock the rear diff at least once every couple of months for a few miles.

Not engaging 4X4 for long periods won't do $1700 worth of damage to the transfer case. It simply won't engage and can usually be repaired by either disassembly, cleaning parts and reassembly. Or replacing corroded electrical components. Operating in 4X4 in hard dry surfaces will do $1700 worth of damage to the transfer case. And the real damage could have been done years earlier. The parts are over stressed and will take some time before they actually fail.

 

Did I miss it somewhere? Is this a 3.3/6spd combination drivetrain?

 

5.0/10 speed.

 

Here is my x-fer case issue in case anyone is interested.

 

I don't think I will buy any ford product after owning my raptor for 20k. replaced couple seal already, transmission is low on fluid from new, and starts to leak...

 

My 2016 has been flawless - 5 years and never been in the shop for any repairs. Now, if you want to hear about repairs I'll tell you about my GMC......

All brands have problems. I just happened to luck out and get a good one.

 

Defintely a lemon situation.

And most people dont go down 10 miles of dirt road just to give the 4wd a workout.
There actually isnt anything wrong with engaging it, just to engage it, on dry pavement as long as you dont make any turns. I do that from time to time. Making turns on dry pavement in 4wd is a no no. And when I do engage it "just to give it a workout" I switch right back to 2wd.

 

If you had 17" tires that would be true, but the 31-32" tires that you actually have rotate about 5 times per second at 30.

The input side of your diff turns (your axle ratio) times for each tire rotation, so if the banging you heard were on that side you'd be getting about 18 of them per second depending on your axle ratio, but certainly too many to individually count.