1996 4x4 not working/grinding

[Bryan1978xlt]

Wondering where I should start with this issue. Truck is a 96 manual trans. When I recently went to put the truck into 4low on trail I noticed a grinding sound even when in I’m in neutral. Also noticed that while the truck was definitely in low front tires were not turning. I assume since I hear the noise even in neutral sitting still it would be a transfer case issue and not front diff, axel, hubs. I have experience working on cars, but this is my first 4x4 vehicle so just wondering if I’m on the right track before I tear into the transfer case. Btw truck is normal when driving around in 2wd, no noise etc.

 

[974X4BLACKSPORT]

From the description of your problem I can gather this: If you hear the grinding in "N", the output shaft to the transmission is not turning, and neither is the t-case, therefore the noise has to be the transmission.
When your in neutral, are you describing the transmission being in "N", or the t-case being in "N"?

 

[Bryan1978xlt]

This truck is a manual 5spd yes I hear the noise as soon as I put it in 4x4 even if I’m parked and in neutral. That is what gets me, I would think nothing in the transmission or transfer case should be moving at that point so why do I hear the noise?

 

[974X4BLACKSPORT]

So, if your parked in neutral, and you put it in 4x4, is the clutch engaged (up) or disengaged (to the floor)?

 

[Bryan1978xlt]

Parked with clutch Engaged, in neutral I hear it. I don’t think it goes away when I disengage clutch either, but I’ll double check in the morning

 

[410Fortune]

does 4high work?
IS the noise there in 2wd?

 

[imp]

does 4high work?
IS the noise there in 2wd?

@410Fortune

He said: "Btw truck is normal when driving around in 2wd, no noise etc."

Significant clue. What is turning in 2WD but not 4X4 LOW, HIGH? imp

 

[410Fortune]

why would the noise be there when stopped in N?
clutch noise?

It sounded like the t case was stuck between N and low, grinding, but you would not hear a t case noise when stopped in N because NOTHING is turning = points to a clutch??? but then goes away? Something is fishy fishy

I was going to suggest that maybe we start with the basics. Does it grind in 4hi?
Are you coming to a full stop and pushing the clutch in, then shifting into low range?

 

[Bryan1978xlt]

Clutch, pressure plate, throw out bearing are fairly new. Changed by a shop by previous owner about 3 years ago just before I bought it. Also strange that there is no noise in 2wd. Might just have to bite the bullet and get under there and figure things out. Just wondering if anyone had a good place to start. This is just an extra vehicle for trails in the mountains and occasional trip around town so if it’s down for a while for me to figure things out it’s no big deal. I’m thinking maybe 4 low isn’t engaging fully and that’s the sound I’m hearing? But then again when I drive in 4low truck is most definitely geared down. Head scratcher.

 

[410Fortune]

You might just need to adjust the shifter linkage for the manual t case
They are adjustable.

Are you coming to a full stop and pushing in the clutch then shifting from high range to low range and vise versa correct?
Have you ruled out the noise to be coming from one of the hubs?

 

[Bryan1978xlt]

My truck is a switch 2wd/4hi/4low. Noise can’t be from hubs as you can hear it when truck is not moving. Besides that I replaced hubs and cv axels last year

 

[410Fortune]

allright its electric shift, that's an important detail.
96 explorer has a CAD front differential, there is a front axle disconnect on the passenger side.....that thing might be stuck between "on" and "off" also which could cause some strage grinding noises


Is this a control trac t case?
If so then you likely need to open it up and fix it

I would check the function of the CAD
Then drain the t case see if the fluid is dark or burnt, see if any plastic bits come out

 

[Bryan1978xlt]

allright its electric shift, that's an important detail.
96 explorer has a CAD front differential, there is a front axle disconnect on the passenger side.....that thing might be stuck between "on" and "off" also which could cause some strage grinding noises


Is this a control trac t case?
If so then you likely need to open it up and fix it

I would check the function of the CAD
Then drain the t case see if the fluid is dark or burnt, see if any plastic bits come out

Cool thanks I’ll check it out. At least I have a place to start now!