How hard to replace Transfer Case on '91???

tpstaples · 07-21-2004, 10:56 AM

Hey guys..

My 91 explorer XLT v6 4x4 has a severe grinding noise when going into 4x4.

It's my assumption that the transfer case is shot. So my question for you enthusiasts is, how hard is it to replace the transfer case??

I can get one pretty cheap, and I'd like to drop the one that's in it out.. and put this other one in.. but i need a step by step on how to do it.

And i dont have a repair manual

can any of you help me out?

Thanks

410Fortune · 07-21-2004, 11:04 AM

Yes, dont start throwing $$$ at it until you know what the problem is.

The transfer case is not hard to replace at all, and you can find a junk yard unit for about $100-200, depending on your area.

Have you checked the fluid level?
Have you attempted to shift it by hand?
Have you gotten under the truck and listened for the origin of the noise?

tpstaples · 07-21-2004, 11:09 AM

Shift by hand??? how would I do that? It's an automatic and I believe it's a floor shift 4x4. I could be wrong. It's actually my parent's old vehicle that they are giving me so i can restore it back to working order.

I'm headed down to my parents to go over the vehicle tonight in and out to see where the problems are.

Apparently my mom said that it makes a horrible noise when trying to engage the 4x4 as if the "bottom of the car were going to fall out" quoting my mom here.

And she said there was a grinding when she was driving in 2wd as well.

I found a 4x4 transfer case for it for 40 dollars plus shipping. Obviously used. I'm thinking of just replacing it for the 40 bucks and seeing what happens.

But i wanted to know how hard it is to replace. Is it just a matter of dropping it out with a few bolts and then installing the new one and meshing it up with the transmission?

Can you tell me whether the transfer case is between the transmission and motor or between the transmission and driveshaft??? i'm not actually sure as i haven't looked at the vehicle yet

Is there anything i'd have to drop before dropping the transfer case? Like the driveshaft or transmission?

is there anything I should replace while i have the transfer case out?

any help would be EXTREMELY helpful

410Fortune · 07-21-2004, 11:14 AM

OKay here you go:

If its an electric shift t case (sounds like it is not, but most of them are) you can unbolt the shift motor from the t case and turn the adjuster by hand.

Make sure she knows how to shift into 4x4

You can shift into 4x4 high range any time, but for low range you must be stopped and in P

The the t case is on the back of the trans.
You will have to remove the front driveshaft
unbolt the rear driveshaft
unhook the wiring to the shift motor and speed sensor.
Pull the clip that holds the speedometer cable in the speed sensor
The alternative is to unbolt the speed sensor (1 bolt)
You will want to remove the skid plate to make things easier
Then it is a matter of 7 bolts I believe that hold the t case to the trans, fluid will spill out, Atf.

You need to replace the gasket between the trans and t case, dealer item.

Easy

Make sure its either electric shift or manual shift before you order a new one.
Manual shift is about 10 times more rare.

tpstaples · 07-21-2004, 11:22 AM

woww..

thanks a lot man.. i really appreciate the help.. and the immediate response.. this board is awesome..

hopefully i'll get to my parents place, find out the problems, fix em and be on my way to a nice 4wd vehicle that I can eventually put a plow on.. and maybe sup up into a 4x4 monster.

Thanks again

MrShorty · 07-21-2004, 01:43 PM

A bad case of grinding or other noises in 4WD is more often a case of bad auto hubs than a bad transfer case.

tpstaples · 07-21-2004, 01:46 PM

hmm.. really?

so what do you guys suggest as the best approach to determining the problem here?

Should i have my father slowly drive the vehicle while I listen for the noise?

if the noise is coming directly from the transfer case, is it safe to assume it's the transfer case that's bad?

Also, could it possibly be the transfer case shifting module?

Thanks again

410Fortune · 07-21-2004, 01:50 PM

OKay start at the top of this thread again.

The hubs wont make noise unless the truck is rolling.
She says it sounds like grinding when trying to engadge 4x4, this means to me since you think it is a manual shift that shes sitting there trying to force it into low range with the truck stopped.

It is possible that the t case has failed, however first thing to do is check the fluid level, it takes ATF.

The shift actuator motor (if it is a push button) will not cause a grinding, you wont hear anything, just a click sound from the buttons and the lights will flash..

tpstaples · 07-21-2004, 02:31 PM

I just spoke to my mother and it is a push button 4x4. So it's electronic shift.

any ideas about what could be going on with electronic shift?

07-21-2004, 10:56 AM	#1
tpstaples Wannabe Elite Explorer grafton, Ma 91 XLT Join Date: Jul 2004 Posts: 53 Vehicle Specs (Original Poster)	How hard to replace Transfer Case on '91??? Hey guys.. My 91 explorer XLT v6 4x4 has a severe grinding noise when going into 4x4. It's my assumption that the transfer case is shot. So my question for you enthusiasts is, how hard is it to replace the transfer case?? I can get one pretty cheap, and I'd like to drop the one that's in it out.. and put this other one in.. but i need a step by step on how to do it. And i dont have a repair manual can any of you help me out? Thanks

07-21-2004, 11:04 AM	#2
410Fortune ELITE BRONCO2ERER Crawlorado B2 Mod Join Date: Aug 2000 Posts: 22,099 Vehicle Specs	Yes, dont start throwing $$$ at it until you know what the problem is. The transfer case is not hard to replace at all, and you can find a junk yard unit for about $100-200, depending on your area. Have you checked the fluid level? Have you attempted to shift it by hand? Have you gotten under the truck and listened for the origin of the noise? __________________ 96 Explorer daily driver build-1996 XLT 5.0L AWD to 4x4 conversion complete on 33's 88 BII 5.0L conversion - BII 5.0l drivetrain thread My Bronco II - 1988 Bronco II 4x4 V8 on 35's - registry and updates Wifes 07 FJ build - 2007 FJ cruiser locked and lifted

07-21-2004, 11:14 AM	#4
410Fortune ELITE BRONCO2ERER Crawlorado B2 Mod Join Date: Aug 2000 Posts: 22,099 Vehicle Specs	OKay here you go: If its an electric shift t case (sounds like it is not, but most of them are) you can unbolt the shift motor from the t case and turn the adjuster by hand. Make sure she knows how to shift into 4x4 You can shift into 4x4 high range any time, but for low range you must be stopped and in P The the t case is on the back of the trans. You will have to remove the front driveshaft unbolt the rear driveshaft unhook the wiring to the shift motor and speed sensor. Pull the clip that holds the speedometer cable in the speed sensor The alternative is to unbolt the speed sensor (1 bolt) You will want to remove the skid plate to make things easier Then it is a matter of 7 bolts I believe that hold the t case to the trans, fluid will spill out, Atf. You need to replace the gasket between the trans and t case, dealer item. Easy Make sure its either electric shift or manual shift before you order a new one. Manual shift is about 10 times more rare. __________________ 96 Explorer daily driver build-1996 XLT 5.0L AWD to 4x4 conversion complete on 33's 88 BII 5.0L conversion - BII 5.0l drivetrain thread My Bronco II - 1988 Bronco II 4x4 V8 on 35's - registry and updates Wifes 07 FJ build - 2007 FJ cruiser locked and lifted

07-21-2004, 01:43 PM	#6
MrShorty Wannabe Elite Explorer Spanish Fork, UT 92 XLT and '87 Bronco II Join Date: Dec 2001 Posts: 4,934 Vehicle Specs	A bad case of grinding or other noises in 4WD is more often a case of bad auto hubs than a bad transfer case. __________________ Mr. Shorty 92 XLT 4x4 87 Bronco II XLT 4x4 '98 Chev K1500 Suburban SLT 4x4

07-21-2004, 01:50 PM	#8
410Fortune ELITE BRONCO2ERER Crawlorado B2 Mod Join Date: Aug 2000 Posts: 22,099 Vehicle Specs	OKay start at the top of this thread again. The hubs wont make noise unless the truck is rolling. She says it sounds like grinding when trying to engadge 4x4, this means to me since you think it is a manual shift that shes sitting there trying to force it into low range with the truck stopped. It is possible that the t case has failed, however first thing to do is check the fluid level, it takes ATF. The shift actuator motor (if it is a push button) will not cause a grinding, you wont hear anything, just a click sound from the buttons and the lights will flash.. __________________ 96 Explorer daily driver build-1996 XLT 5.0L AWD to 4x4 conversion complete on 33's 88 BII 5.0L conversion - BII 5.0l drivetrain thread My Bronco II - 1988 Bronco II 4x4 V8 on 35's - registry and updates Wifes 07 FJ build - 2007 FJ cruiser locked and lifted

07-21-2004, 11:09 AM	#3
tpstaples Wannabe Elite Explorer grafton, Ma 91 XLT Join Date: Jul 2004 Posts: 53 Vehicle Specs (Original Poster)	Shift by hand??? how would I do that? It's an automatic and I believe it's a floor shift 4x4. I could be wrong. It's actually my parent's old vehicle that they are giving me so i can restore it back to working order. I'm headed down to my parents to go over the vehicle tonight in and out to see where the problems are. Apparently my mom said that it makes a horrible noise when trying to engage the 4x4 as if the "bottom of the car were going to fall out" quoting my mom here. And she said there was a grinding when she was driving in 2wd as well. I found a 4x4 transfer case for it for 40 dollars plus shipping. Obviously used. I'm thinking of just replacing it for the 40 bucks and seeing what happens. But i wanted to know how hard it is to replace. Is it just a matter of dropping it out with a few bolts and then installing the new one and meshing it up with the transmission? Can you tell me whether the transfer case is between the transmission and motor or between the transmission and driveshaft??? i'm not actually sure as i haven't looked at the vehicle yet Is there anything i'd have to drop before dropping the transfer case? Like the driveshaft or transmission? is there anything I should replace while i have the transfer case out? any help would be EXTREMELY helpful

07-21-2004, 11:22 AM	#5
tpstaples Wannabe Elite Explorer grafton, Ma 91 XLT Join Date: Jul 2004 Posts: 53 Vehicle Specs (Original Poster)	woww.. thanks a lot man.. i really appreciate the help.. and the immediate response.. this board is awesome.. hopefully i'll get to my parents place, find out the problems, fix em and be on my way to a nice 4wd vehicle that I can eventually put a plow on.. and maybe sup up into a 4x4 monster. Thanks again

07-21-2004, 01:46 PM	#7
tpstaples Wannabe Elite Explorer grafton, Ma 91 XLT Join Date: Jul 2004 Posts: 53 Vehicle Specs (Original Poster)	hmm.. really? so what do you guys suggest as the best approach to determining the problem here? Should i have my father slowly drive the vehicle while I listen for the noise? if the noise is coming directly from the transfer case, is it safe to assume it's the transfer case that's bad? Also, could it possibly be the transfer case shifting module? Thanks again

07-21-2004, 02:31 PM	#9
tpstaples Wannabe Elite Explorer grafton, Ma 91 XLT Join Date: Jul 2004 Posts: 53 Vehicle Specs (Original Poster)	I just spoke to my mother and it is a push button 4x4. So it's electronic shift. any ideas about what could be going on with electronic shift?