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  1. R

    How to: Rebuild 4X4 Shift Motor

    Found someone that knows how this system really operates. Check out the last page in this very informative link: http://www.rsgear.com/articles/2008_05.pdf If you do not have stability control (like me), the xfer case speed sensors do all the work of detecting slip between front and rear...
  2. R

    How to: Rebuild 4X4 Shift Motor

    I think your Edit is correct. I do not believe I have a VC xfer case. I was under the impression the AWD Ex's had those. 4x4 Ex's (I have 3 buttons, 4x4 Auto, 4x4 High, 4x4 Low) I thought had locking xfer cases. The 'Auto' mode accomplished by sensing wheel slip and auto locking the xfer case...
  3. R

    How to: Rebuild 4X4 Shift Motor

    Tire sizes all check out. Used string to measure, all exactly the same. Is there a way to temporarily disable the 4x4 so I can drive while I figure out the fix? Tried pulling fuse 17 & 18 (20A) under the hood, that control 4x4. Tried unplugging 4x4 CM. Still stuck in 4x4. Is the xfer case...
  4. R

    How to: Rebuild 4X4 Shift Motor

    OK, futher research tells me the xfer case uses speed sensors mounted to xfer case, one for front driveshaft, one for rear (ABS sensors used for traction control and AdvanceTrac, which I don't have). So either I have tire size differences (uneven wear), or bad speed sensor(s) (I think)...
  5. R

    How to: Rebuild 4X4 Shift Motor

    ok, all 4 corners on jackstands, I can move the xfer case shaft now. What I found is, the N really does mean Neutral, not 2H as I had assumed. There is no detent for N, anything that is not or L is just a free floating Neutral space. When xfer case is in N, even though trans in D (or R, or...
  6. R

    How to: Rebuild 4X4 Shift Motor

    Thanks, will try lifting an axle, and putting trans in Neutral. Is this thread exclusive to 2nd gen Ex? Never saw that spelled out in the thread. If my hubs (which are auto) were stuck, that would just mean I would be spinning the front axle and front driveshaft unnecessarily, right? I...
  7. R

    How to: Rebuild 4X4 Shift Motor

    Help! Stuck in 4x4. With the shift motor off, can't manually rotate the xfer case into 2H. I can turn it past 2H, but it won't click into place. Soon as I let go the pliers, it spins back to 4H. 2002 Ex EB, ~200K miles. Went to drive it, found it was stuck in 4x4. Had driven it earlier in the...
  8. R

    Good trans shop in CT

    Looking for recommendations for a good trans shop in CT. I have an '02 Ex EB, 165K miles, servo bore failure, need a rebuild (been driving this way for a while, and now OD band can barely be adjusted its so worn out). So I know I'll need the servo bores sleeved, and at least a soft parts...
  9. R

    Need transmission rebuilt (5R55W) and advice

    Ditto. I'm in the same boat, looking for the same answer. 02 Explorer, EB 4x4, 150K miles, servo bore wasted, no 2nd & no OD, plus light flashing constantly. I can replace the tranny myself if I can find a decent deal on a properly rebuilt unit (with sleeved servo bore, etc). Also game for a...
  10. R

    no heat - dual climate control

    Yeah, in my case it was just low on coolant due to a leaky oil cooler line (not sure if this is a towing package thing or if all Ex (& Mounty) have them, but I have coolant lines that run from water pump to oil filter then return into the heater core hoses - there is a mini radiator between oil...
  11. R

    5r55w, replaced solenoids, better, but still not right

    Bump, nobody has any ideas? Glacier, BrooklynBay, Bueller?
  12. R

    difficult to insert ignition key

    You can get a new lock cylinder from AutoZone? I would have thought that was a dealer only item.
  13. R

    difficult to insert ignition key

    Found a write up on the Focus forum about how to change the cylinder. I figured they would use a similar cylinder, both Ford PATS products, and indeed, one of the posts in the thread mentions using an Explorer cylinder as a replacement for the Focus unit (implying they are compatible, which...
  14. R

    difficult to insert ignition key

    Thanks BB! So if the cylinder is replaced, does that require a new ignition key? Won't be fun to have a different key for doors vs ignition (though I use the remote most of the time, so its not THAT bad).
  15. R

    5r55w, replaced solenoids, better, but still not right

    2002 EB 4.0 4x4 ~115K miles. I bought the truck with ~107K miles, and noticed a 2-3 flare. So while I waited to get around to fixing it, I really babied it (also had a rattlin' timing chain, another reason I was babying it). Finally did the solenoid pack (and the timing chain tensioners)...
  16. R

    difficult to insert ignition key

    Ever since I bought my '02 EB (100K miles), it has been difficult to insert the key in the ignition (been going on for several months now). The key is not excessively worn. I tried lubing the lock, sprayed a bunch of silicone in there, didn’t help. Its usually not very difficult to get the key...
  17. R

    2004 Ford Explorer timing chain tensioner was replaced, and it won't start.

    There are no timing marks on this motor. The timing has to be set with a special tool that holds the cams in place, as the timing is variable and held in place by the bolts that mount the gears to cams. If you loosened any of those bolts, you'd need the tool to get the timing back in place...
  18. R

    02 Engine wont start in cold weather

    Mistake 1, going to delaer. Never heard of that turning out well. But now that you did, and paid them, make them get it right. I think their thinking was, no fuel getting to engine, but FP electrical OK (in fact, pump is running), then it must be the FP. Even when they already replaced it...
  19. R

    Ford Explorer 2004 Overheating/No heat

    Its overheating as in steam pours out, or is it just the gauge that says its overheating? Are there actual overheating symptoms besides just the gauge? (maybe its just the sending unit or an electrical problem with the gauge?) Somebody else suggested the thermostat, even though you already...
  20. R

    Tranny in shop, I'm getting boned, please help!

    That is a scumbag strategy some shops pull, tell you its probably not as bad as you thought, to convince you to have them do the work, then they 'find out' it is as bad as the last shop said, then hit you with a whopping estimate. Usually this comes with a lot of bravado about how they are...
  21. R

    noise on acceleration

    Cool, thanks!!! The short version of long story is a had a '99 Ex SOHC, with death rattle @ 2-3K rpm's. Always thought it was ping. Learned from this forum about TSB, realized that is what it was. Had local, trusted shop change jackshaft tensioner, 2 days later I got some serious rod knock...
  22. R

    loud engine knock, need help

    yes, could be flywheel or torque converter. Does it sound like its coming from up front, or down below? You say you checked your 'pullys'. You mean idler pully, alt, power steering, etc? The sound you describe could be any of those. Easy enough to temp remove serp belt and see if noise goes...
  23. R

    noise on acceleration

    maybe its the serpentine belt tensioner? How many miles (both you 2005 guys)
  24. R

    noise on acceleration

    Chill, just because YOU had a noise which wasn't the tensioner doesn't mean no one else can have a noise that IS the tensioner. Lots of people on this board, including myself, had a noise which sounded a whole lot like ping, and it was the jackshaft tensioner. There is a Ford TSB on it, so...
  25. R

    02 Explorer quit on highway

    what about the fuel pump circuit breaker? Its under the passenger kick panel. Owners manual should show how to access it and how to reset it.
  26. R

    noise on acceleration

    The timing chain rattle (the tensioner goes bad) affects SOHC motors. It sounds a whole lot like ping, but its only audible between 2K-3K rpm's, most noticible at 2.5K. It does not affect engine power. It will only get worse, you will eventually have to get it fixed, and the new part is...
  27. R

    no heat - dual climate control

    First winter with the new '02 EB Ex (with dual climate control), and I find the heat doesn't always work. Sometimes it does, sometimes it doesn't. I don't hear any clicking or clunking that I've read is indicative of a stripped blend door actuator. Over the summer the A/C seemed to work fine...
  28. R

    What is 4X4 Auto?

    There is a multitude of vehicles out there that are marketed with the term 'AWD', but are predominently 2wd, applying power to the other 2 wheels only when slippage is detected. Sometimes the predominantly driven wheels are the front 2, sometimes the rear 2. Other vehicles that use the AWD...
  29. R

    engine rattle/vibrate

    What rpm is it idling at? I'm thinking maybe its just too low idle speed, and that results in the vibrations, along with maybe a heat shield rattle (on the CAT or other exhaust part). If it is idling too low, remove and clean your IAC valve (Idle Air Control), then after you reinstall, set...
  30. R

    What is 4X4 Auto?

    The Auto 4x4 is simply a form of AWD. There are two types of AWD, Full Time, and Part Time. Vehicles that drive all 4 wheels all the time are Full Time, while the Ex Auto 4x4 is of the Part Time variety (its rear wheel drive unless the rears spin, in which case the center diff sends some power...
  31. R

    4x4 does not work

    FIXED! It was the switches, PO left them unplugged. Must have been doing some service of radio or sumthin' and neglected to plug them back in on reassembly. Switches are accessed by popping off bezel around radio/heater.
  32. R

    replaced 4x4cm, still no 4x4 - '02

    Fixed! It was the switches. They weren't even plugged in. PO must have been in there working on it and forgot to reattach the connector on reassembly (4x4 has never worked since I got the truck amonth ago). I was a little suspicious of something like this as the radio was very loose. They...
  33. R

    replaced 4x4cm, still no 4x4 - '02

    Bump. What do I look at next? None of the 3 switches light up when the headlights are on. No sound at all from the 4x4cm (relay click or anything) when trying to activate 4x4. When starting the 4x4 hi & lo dash lights go on, hi goes out, then lo goes out. Not sure what is normal since it...
  34. R

    loud engine knock, need help

    The idler pully is the only one that isn't attached to an accessory (not the alternator, not the water pump, power steering, A/C, etc.) You use a 3/8 drive ratchet (with no socket attached) to loosen the belt by fitting into the square hole in the idler pulley bracket. Once hte belt is off...
  35. R

    replaced 4x4cm, still no 4x4 - '02

    FIXED! I have all the classic 4x4cm symptoms, no lights on dash, no lights on 4x4 buttons, nothing happens you press any of the buttons (no lights, no sounds, nothing). Its an '02 EB, 4.0, 108K miles, with an early build date (0201) which I just purchased. The 4x4 didn't work when I got it...
  36. R

    Sloppy Shifts - 5r55w

    Yea, that is the first place I tried, but they are out of stock acording to their web site: http://www.transmissionpartsusa.com/5R55S_5R55W_transmission_solenoid_s/11798.htm Where else can I buy them?
  37. R

    Sloppy Shifts - 5r55w

    Where can I buy the solenoid pack? Places I've looked (that were posted here) were out of stock. Truck has 108K miles. I'll look at the VB gasket and check bolt torque. But what part of the gasket am I checking? Do I have to remove VB to check? Also, what is the bolt torque?
  38. R

    4x4 does not work

    '02 Ex EB, recently purchased. 4x4 not working, no lights, nothing. Fuses OK. So I find this thread, and sure enough, there is a new battery in this thing, sticker says was repalced in Oct '07. So its gotta be the 4x4cm, right? Well after replacing, its still not working. Got the new module...
  39. R

    Sloppy Shifts - 5r55w

    Just bought an '02 Ex EB w/ about 107K miles, and noticed the shifts are pretty sloppy (compared to the '99 Ex, 5r55e I'm used to). It kinds slushes into the next gear (seems to be all gears, just more noticable at some speeds & rpms than others). I don't know the history, so I was going to...
  40. R

    5R55W flush procedure?

    So reading the posts on 'flushing' the tranny fluid, I see that the cooler lines don't suck any fluid in, just push old out. So you can't just use two buckets (one with clean fluid) and do a fluid flush. What was mentioned in those threads was to keep starting and stopping motor, to pour a...
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