04 Ford explorer transfer case issues

[Clee]

I am having trouble tracking down a problem I am having on my 04 explorer, I can drive down the road and the wrench light on the dash pops on and it goes into a false neutral like its in between 2 wheel and 4 wheel and makes that gear grinding noise, I ran the code reader and did the whole google search and found a bad ground wire on the actuator motor harness on the back of the transfer case, fixed that and still have the same problem the only code that I got and wished I wrote it down was for a "bad electric clutch relay circuit " now I am looking for the clutch relay and have had no luck what so ever in even finding anyone who has had the same problem. PLEASE HELP!!!!!!! this is my only ride and being so close to Xmas money is super tight

 

[imp]

I am having trouble tracking down a problem I am having on my 04 explorer, I can drive down the road and the wrench light on the dash pops on and it goes into a false neutral like its in between 2 wheel and 4 wheel and makes that gear grinding noise, I ran the code reader and did the whole google search and found a bad ground wire on the actuator motor harness on the back of the transfer case, fixed that and still have the same problem the only code that I got and wished I wrote it down was for a "bad electric clutch relay circuit " now I am looking for the clutch relay and have had no luck what so ever in even finding anyone who has had the same problem. PLEASE HELP!!!!!!! this is my only ride and being so close to Xmas money is super tight

As a quick fix, to stop the noise and allow driving of the Ex, you can simply disconnect the connector at the transfer case, which will remove any possibility of the electronic clutch being erroneously activated. Such activation on pavement can be real hard on the drive line. Disconnecting it will, of course, allow only rear wheels to drive the vehicle, no 4-wheel available at all.

This is assuming there is not some kind of mechanical problem within the transfer case. Note that running with transfer case connector disconnected will result in "throwing" the ABS light "ON", and probably "4X4 LOW" light "ON" as well. imp

 

[drdoom]

What is the condition of your tires? They must match EXACTLY, size, brand, model, treadwear, and inflation. Proper and frequent rotation is critical for the above to remain true for the service life of the tires.

 

[imp]

What is the condition of your tires? They must match EXACTLY, size, brand, model, treadwear, and inflation. Proper and frequent rotation is critical for the above to remain true for the service life of the tires.

Dr., you're right, of course. I've wondered how wide a "fudge factor" Ford built into this. Obviously, given realistic numbers regarding tire diameters, inflation differences, differing tread design, even, there is NO WAY that all four tires will present EXACTLY the same rolling diameters dynamically, while operating.

So, I purposely messed with sticking one worn tire on my '04, driving it, noting results. The other three were brand new. The "rag" was half-tread gone. Know what happened?

Not a damned thing. No "ABS", no warnings of any kind. So, then I figured if the original tread depth is factored against the tire O.D., that 50% of the tread gone represented a % difference from new. It came out to be about 2%. 3/8" on the diameter, 3/16" tread gone on the radius.

I concluded that if the four tires are all within 3/8" diameter of each other, the 4X4 AUTO function will compensate for the difference, all based on what Ford Engineering used in their PCM software.

The "kicker" in all of this is, it's really difficult to measure the rolling radius of a tire. It has many variables. Suffice to say that, if all 4 tires are of the same NOMINAL listed size, i.e., say, 235-70-R16, no problems should arise UNLESS one of them is worn clean down to the cords! imp

 

[-Greg-]

I think I have same issue. I engaged 4x4low and when I pushed the accelerator car had a noticable cling and lost all power (I did push the pedal to the floor, I was on a steep hill). No error codes at first, but car would not move. Engine was running good and speedometer reacted, but car did not move at all. I tried going to Park and then Drive again but wrench bulb came up and the car was still not engaging any gear (at least I was not getting any pulling power). As if the transfer box went to neutral. I started pushing 4x4 auto and 4x4 low, giving the car time to light up relevant bulbs in the instrument cluster and on sound 7th try car engaged 4x4 auto. Now I don't know what happened and if this might happen again. Any ideas what is wrong?
This is the video of me trying to move after engaging D on a gearbox

 

[-Greg-]

Sorry, forgot to attach the link to the Video