Pirate, Thanks for the great explanation for those of us who are clueless!!!
Awesome jd and pirate, thanks!
No problem guys.
What can we do to stop this from hapenning...if anything?
I'd like to know too.
B, I was gonna ask, are you pretty sure that bang we heard came from the rear, and maybe not the front hub? Know what I mean?
As far as I know there's not much you can do. Its a crummy system imo. Ford has tweaked it over the years and it has gotten somewhat more reliable. I try to do as little shift on the fly as possible. I'll try and come to a stop and give the hubs a chance to cleanly engage/disengage when not under load. Before I hammer it, I make sure the hubs are locked/unlocked as need be. This works the hub teeth as little as possible. If the hubs begin to chatter its best to drive it as little as possible to avoid extra damage. Unplugging the EWI so it's not trying to half way engage is something else I would do.