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Yes ... Running perfectly ! **** changes now with new full synthetic fuid & new filter are great. I'm very happy with saving AUD $1400 by doing the job myself ! :-)

Hopefully this might help ???

Here are the exploded views of the transfer case + parts listing so you can see what I mean from my previous suggestion ...

Okay ... so if you really are stuck with this other transfer case & can't return it ... If it were me, I'd be seeing if I could remove the rear cover off the replacement transfer case & swap it with the rear case from your original transfer case ... provided it phyically fits & that the...

Success :-) Mission Accomplished !!! Got my torque converter back yesterday afternoon from being re-built ... they fitted a new modified 'Sonnax' piston with friction material affixed & removed the standard factory fitted 'clutch plate'. Apparently this is a quite common modification for...

YES ... I was refering to the Front Output Shaft Sensor located behind the shift motor ... And the Rear Output Shaft Sensor located under the rear output shaft ... I'd imagine if both the transfer cases you have in front of you are physically the same then swapping over the ancillary...

I had a similar noise on my 05 Eddie Bauer LHD that we have in da Phillypeens ... found ALL of the body mount rubbers were rotted completely away at the location you indicated. I ended up fabricating some home made bushes by cutting some circles out of a thick truck inner tube, glued the stack...

This might help ? I just checked my RH drive 03 XLT 4.6, as I have the transfer case out of the vehicle & it has a 15pin plug. Checking the wiring diagrams I have it appears early 4WD WITHOUT traction control have a front & a Rear speed sensor & associated circuits that the later models...

Heard back from the transmission shop today about the progress on the converter at the specialist re-builders ... upon opening it up they found the entire lock up clutch friction material had separated from the piston and was just floating & getting broken up inside the converter. They took...

I just found a separate 2005 Supplement in the manual ... Shows the same thing ... interior light circuit controlled by microprocessor in the instrument cluster: The Instrument cluster diagram shows all the door ajar switches reporting to a separate Vehicle security microprocessor which...

Yes .. I should have read them properly instead of 'skimming' :( Looking at the late model wiring diagrams shows the actual 'control' of the interior light circuit is performed by the microprocessor in the instrument cluster: Which feeds the interior light circuit: Would seem...

I would imagine so ... but the door ajar / dome light staying on might be a different door than the drivers door causing the issue ... maybe ? :)

Old bush mechanics method of 'sealing' head gaskets was to spay both sides of the head gasket with a few coats of fake chrome / silver pressure pack paint. Let them tack off before fitting onto the block mounting face / dowels & sitting the heads on top. A sentiment I whole heatedly agree...

Door ajar & dome light staying on are obviously related ... good explanation on how to fix is here: https://www.youtube.com/watch?v=egIGBzO065U

PMSL ... now THAT is an honest answer !!! :D

Update :-) Update on diagnosing this 'rattle' ... Pulled the front cover off AGAIN thinking maybe the RH tensioner was not getting enough oil pressure ... but alas ... wasted a whole day & found nothing out of the ordinary ! Tensioners were tight & pressurised with oil ... so that discounts...

I just did the same job a month ago without any special tools & had almost the exact same experience ... the left side remained lined up well whilst I replaced the guides & tensioner ... but the right side rotated a few teeth. Using a 1/2" drive extension bar, I simply put it thru one of the...

Radio Unlock Code I had the same dilema ... the local Ford dealer wanted AUD $100 to get it 'unlocked' ... sooooo after a little internet investigation I found, downloaded, unzipped & ran a small program that generates the unlock code. You need the serial number off the side of the radio to...

4.6 Timing Chain Replacement - SUCCESSFUL OUTCOME ! Recently purchased a 2003 Exploder with 4.6 travelled @ 250K Km = 156K miles. :eek: When I viewed the vehicle, the engine oil was brand new & it drove really well inc the auto shifting smoothly.The engine oil looked like it was a lot...

Easy fix to simple problem :-) Most definately ... had the same issue last week but checked the bulbs with a multi meter & found only the one filament was good in both bulbs, namely the tail light filament :( A couple of replacement bulbs were sourced & tested ... all good BOTH filaments...