1. for access to reviews and discussion of the 2016 and 2017 Ford Explorer, Tech Tips, How to Articles, Off-Road Modification, Events, and more!

    Register Today It's free! This box will disappear once registered!

Remove front driveshaft on AWD Mountaineer

Discussion in 'Stock 2002 - 2005 Explorers' started by cbrock, October 4, 2010.

  • Searches ExplorerForum.com
    1. cbrock

      cbrock New Member

      Joined:
      February 12, 2006
      Messages:
      27
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Athens, GA
      Year and Model:
      05 Infiniti G35 Coupe 6MT
      I believe I have a bad transfer case causing a thumping noise when in motion. Is it safe to completely remove the front drive shaft and only rely on RWD from here on out? Or at least until I can afford a new xfer case. One local shop tells me that removing the front shaft will throw an error code and screw up the transmission but that is contrary to what I've read on here. I don't need the AWD since I live in GA where it snows once every 5 years, and no way I'm getting on the roads with other nutjobs in those conditions!!

      If it is safe to remove, how do I go about doing so? I wasn't able to find any instructions by searching.

      Any help is greatly appreciated in advance!!

      -Chris
       
    2. Support EF


      Join the Elite Explorers for $20 a year

      Explorer Forum has probably saved you that much already, and will continue to save you money as you learn how to diagnose and fix problems yourself, and learn which modifications work without having to experiment on your own. Elite Explorer members see practically no ads, add your own profile photo, upload photo attachments directly to your posts and Media Gallery, create more private Conversations, and more. Join Today. Your support is greatly appreciated.



      to hide adverts.
    3. Mussin

      Mussin Member

      Joined:
      February 24, 2008
      Messages:
      97
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Lima,Ohio
      Year and Model:
      '02 Mountaineer
      My t-case went out on my 02 mounty and I removed the front drive shaft to see if it was the T- case. I drove it like this for 2 weeks no problems here.
       
    4. mountaineer02

      mountaineer02 Member

      Joined:
      February 17, 2010
      Messages:
      84
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      SLC, UTAH
      Year and Model:
      2002 MONTAINEER
      Yah, I thought I had a bad viscous coupling so i disconeccted mine aswell, I didnt seem to have any problems. theres like 6 small bolts that connect it to the transfer case( i recomend a universal socket joint and some extention) and starbit or something to take off the universal joint on the front diff.
       
    5. muhl5443

      muhl5443 Active Member

      Joined:
      December 10, 2007
      Messages:
      265
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Minnesota
      Year and Model:
      '98 XLT
      there are about 6-8 8mm bolts on the transfer case end and you will need a t30 torx bit to disconnect the u joint from the front diff. there are four bolts there.
       
    6. stuartr

      stuartr Active Member

      Joined:
      January 18, 2010
      Messages:
      421
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Richlands, VA
      Year and Model:
      2002 Mercury Mountaineer
      But will this throw a code or kill the tranny? I bet it would help the MPG on mine.
      STU
       
    7. imp

      imp Well-Known Member

      Joined:
      November 12, 2009
      Messages:
      2,359
      Likes Received:
      29
      Trophy Points:
      68
      City, State:
      Missouri Ozarks
      Year and Model:
      2004 XLT
      Your transmission will not have a clue that the front shaft is missing. I drove my '04 with the front shaft OFF the vehicle for quite awhile, no trouble code generated, no problems.

      But, it strikes me that IF you are experiencing some problem within the transfer case, how will front shaft removal change anything in it? Everything in the AWD design turns ALL the TIME, so unless the noise is originating AT, or FORWARD of, the viscous clutch powering the front shaft, it seems doubtful conditions will change with the shaft removed.

      If you go ahead, the transfer case end MUST be disconnected first, according to Ford Shop Manual, to avoid damaging the seal boot within the coupling, which consists of a funky-looking C-V joint. The shaft is connected to it by 6 bolts which are loc-tited in place at the factory; I broke 2 sockets loosening them. The front end of the shaft needs a Torx key to remove the 4 screws fastening the straps which secure the standard-type U-joint there.

      I hate those Torx jobbies, so replaced mine with Grade 8 Socket Head Cap Screws- they are 1/4-inch 28 thread bolts, good old standard non-metric! The transf. case end ARE metric, I forget the size, but I replaced them with SHCS screws also. imp
       
    8. cbrock

      cbrock New Member

      Joined:
      February 12, 2006
      Messages:
      27
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Athens, GA
      Year and Model:
      05 Infiniti G35 Coupe 6MT
      Thanks for the clarification fellas. I'm going to try and undertake this over the weekend and hopefully I don't screw anything up hah.

      Also, does anyone know if there is a (harmonic?) balancer attached to the front driveshaft somehow? Friend and I were pressing in new upper and lower ball joints last weekend and couldn't figure out what some of the components were up front :/
       
    9. billybob3358

      billybob3358 New Member

      Joined:
      June 29, 2010
      Messages:
      31
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Chuckey, Tennessee
      Year and Model:
      2001 Mercury Mountaineer
      i took minb e out had no prob except if u dont put ur emergency brake on it will roll away
       
    10. Infinity08

      Infinity08 Active Member

      Joined:
      October 29, 2007
      Messages:
      555
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Charlestown, IN
      Year and Model:
      '08 Sport Trac LTD
      Is the transfer case sealed still with the drive shaft removed?
       
    11. Infinity08

      Infinity08 Active Member

      Joined:
      October 29, 2007
      Messages:
      555
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Charlestown, IN
      Year and Model:
      '08 Sport Trac LTD
      Will the transfer case leak fluid with the drive shaft out?
       
    12. worshiprocker

      worshiprocker New Member

      Joined:
      November 15, 2010
      Messages:
      38
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Mesa, AZ
      Year and Model:
      1997 XLT 4x4
      I was driving with out a front drive shaft and didn't have any problems.. but mine is 4x4 not AWD
       
    13. rhyno

      rhyno Active Member

      Joined:
      January 29, 2002
      Messages:
      544
      Likes Received:
      0
      Trophy Points:
      16
      City, State:
      Potomac, MD
      Year and Model:
      1997 EB
      It is still sealed after the shaft is removed, and no it will not leak. (unless you have other issues that would cause it to leak)
       
    14. zimm814

      zimm814 New Member

      Joined:
      February 23, 2014
      Messages:
      2
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      altoona, pa
      Year and Model:
      2002 mercury mountaineer
      Did you notice any 1st gear problems? I removed my front driveshaft and my 1st gear doesn't respond well wondering if it was normal? drives fine after 1st.
       
    15. sulaco83

      sulaco83 New Member

      Joined:
      August 17, 2013
      Messages:
      40
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      West Norriton, PA
      Year and Model:
      1998 Eddie Bauer 5.0 AWD
      Your transmission should shift the same as it did with the front shaft installed. Mine was out when I bought the truck and shifted absolutely fine. Sounds like something else is wrong.... maybe VC is slipping?
       
    16. raveoli67

      raveoli67 New Member

      Joined:
      December 2, 2013
      Messages:
      3
      Likes Received:
      0
      Trophy Points:
      0
      Year and Model:
      2002 mountaineer
      same issue

      trying this weekend..
       
    17. cwol97401

      cwol97401 Member

      Joined:
      October 2, 2014
      Messages:
      86
      Likes Received:
      2
      Trophy Points:
      8
      City, State:
      Duck Country Oregon
      Year and Model:
      1997 Merc Mounty 5.0L
      new question on an old thread, I damaged my front left axle splines at the hub, if I remove the front axle, will I be able to drive the truck normally on the street without the front left tire jumping the axle on takeoff? and someone said that it is necessary to set the parking brake if it is removed, is this correct? because my parking brake hasn't worked for a while now
       
    18. pet575

      pet575 Active Member

      Joined:
      June 11, 2008
      Messages:
      529
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Kansas City, MO
      Year and Model:
      2004 Limited
      How would you "jump the axle" if it is missing? It should drive normally without the axle. If you are that worried about it, disconnect the front driveshaft.

      The parking brake has nothing to do with it.
       
    19. cwol97401

      cwol97401 Member

      Joined:
      October 2, 2014
      Messages:
      86
      Likes Received:
      2
      Trophy Points:
      8
      City, State:
      Duck Country Oregon
      Year and Model:
      1997 Merc Mounty 5.0L
      My wheel is currently jumping the axle at the hub. That is why I want to disconnect the front driveline. It started when the wrong size spare got put on it and drove for 12 miles
       
    20. PeteD

      PeteD New Member

      Joined:
      January 28, 2015
      Messages:
      5
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Long Island, NY
      Year and Model:
      2006 Explorer 4.0 XLT 4x4
      Worth disconnecting front drive shaft if hub/Bearing is about to fail?

      cwol97401, I think I may have the same issue as you have (or hopefully had, I know the last posts to this thread are a few months old)

      It seems my front hub(s) and possibly CV joints are bad, have been for about the last 3k making bearing, growling, humming sound under acceleration, and now an increasingly worse jumping sensation.

      Odd thing is, once I get to 30 and I set the cruise control, it quiets down but isnt silent, however the awful clunking stops once cruise control is set.

      I need to wait 1 week until I will be able to replace my hubs/CV Joints, but right now I am hearing sounds which are really worrying me about potential bearing failure being imminent. I only drive around town and less than 10miles per day as of lately, so I really dont want to break down and I am trying to figure out if there is anything I could do to decrease wear to my front driveline.

      I see I would need t30 star bit for i believe 6 bolts to remove u joint from t case, I am trying to see if there is anything other than this that I could do to disable my front end from receiving power with just the basic tools I carry, preferably after work here in the parking lot I would like to attempt it- I heard about the "BWM" Brown wire mod, I dont want to do anything too drastic but I am wondering, does anyone know if there is a fuse I could pull, or some other way around removing those star bits that wouldnt take too long or be too difficult to accomplish, with temps out there in the teens? thanks
       
    21. PeteD

      PeteD New Member

      Joined:
      January 28, 2015
      Messages:
      5
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Long Island, NY
      Year and Model:
      2006 Explorer 4.0 XLT 4x4
      Also, wanted to mention I did make a post describing more of the bearing/hub issues I have had and why I am feeling this is very serious- 6 months ago I actually had my rear wheel snap off at the axle due to a previous bearing failure. Post is somewhat lengthy but here it is:

      http://www.explorerforum.com/forums/showthread.php?p=3382292#post3382292

      I greatly appreciate any imput
       
    22. pet575

      pet575 Active Member

      Joined:
      June 11, 2008
      Messages:
      529
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Kansas City, MO
      Year and Model:
      2004 Limited
      PeteD, don't let that driveshaft removal intimidate you! If you can change a tire you do this! One tip: find a way to mark the alignment of the shaft with the mating yoke (if that is what it is called) on the front diff so that it goes back in exactly as it was before you took it out.

      It really is pretty easy to do. I had never done anything like it before and I had it out in less than 30 minutes.

      Get that tool that you need, though. Also, do it when the vehicle is cool. You'll be working right near exhaust pipes that you might have to put your arm on to remove a few of the bolts.
       
    23. cwol97401

      cwol97401 Member

      Joined:
      October 2, 2014
      Messages:
      86
      Likes Received:
      2
      Trophy Points:
      8
      City, State:
      Duck Country Oregon
      Year and Model:
      1997 Merc Mounty 5.0L
      Hi PeteD. My mounty had, what I thought, the hub skipping the axle but I may have been somewhat wrong in my assesment. I have no way to get the truck into the air to test it all out but I am thinking now that instead of the wheel hub / axle skipping, the problem was inside the transfer case itself and was caused by a stretched xfercase chain.

      I found out the hard way one afternoon through catastrophic failure of the gearbox. I was driving down an alley leaving a restaurant and all of the sudden my front axle froze solid like I hit the front brakes all by themselves without ABS. I stopped, tried to move the truck and it would only move in reverse. I backed into a parking spot and got underneath to try to figure out what happened. I was in for a surprise.

      I had my spouse attempt to move the truck back and forth while I watched and listened. Then looked at the transfer case. To my shock, a quarter of the case housing has disappeared. I had her move the truck a few more times while I watched the gears inside with fascination and wonder at my new delima. All of the sudden an end of the xfercase chain spilled out of the opening. I grabbed it and worked it the rest of the way out and was able to drive home. On the drive home. I noticed all of the noises had stopped and the steering was much more free than it ever has been and there is a noticeable decrease in torque from the loss of the front wheels driving. The tradeoff now is I have to find a new transfer case and get it installed asap. This rig is my only one and was my daily driver. Bicycling in the winter in the pacific NW is not difficult but it sure can be wet.

      Edit: the brown wire mod will not work on an AWD explorer or mounty because the drive system is purely mechanical. There is no brown wire, or any wire, to modify for two wheel drive.:roll:
       
      • Like Like x 1
    24. 2002 Mercury MT

      2002 Mercury MT New Member

      Joined:
      March 14, 2015
      Messages:
      1
      Likes Received:
      0
      Trophy Points:
      0
      Year and Model:
      2002 Mercury mountaineer
      Rubbing noise when turning and backing up

      I have a 2002 Mercury mountaineer AWD, when I turn sharp or backup and turn sounds like it binding! Can I remove the front drive shaft and be ok? Is there also a fuse to remove? Please help! Thanks
       
    25. cwol97401

      cwol97401 Member

      Joined:
      October 2, 2014
      Messages:
      86
      Likes Received:
      2
      Trophy Points:
      8
      City, State:
      Duck Country Oregon
      Year and Model:
      1997 Merc Mounty 5.0L
      Take the front drive line off. Your viscous coupler has failed causing essentially full time 4 wheel drive. Removing the drive line we'll help but search this forum about it before you jump in because there are things to watch out for after its out.
       
    26. Doyle Durham

      Doyle Durham New Member

      Joined:
      July 24, 2016
      Messages:
      6
      Likes Received:
      0
      Trophy Points:
      1
      City, State:
      Beaverton, Oregon
      Year and Model:
      98 Ford Explorer LTD 5.0

      It seems like you suffered the same issue that I am currently facing with my 1998 AWD 5.0 Explorer... I've seen no physical damage to my Transfer Case, but if the Chain is Stretched or Broken inside, would it prevent the Front Axle from turning?
       

    Share This Page








    We Support Our Troops!