1996 Transfer Case/Binding Problems

[Rickwhite1991]

So i have a 1996 (December) Manual Explorer, basically the 4x4 system really does not work.

When i got it, it would bind alot when first started, then seemed to "loosen up".

Then i unplugged the transfer shift motor, and hey presto worked like a normal 2wd and used it for 2 weeks like that.

Plugged it back yesterday to try and get back to fixing the issue, for the first attempt i got it to shift (or atleast the dash said) into 4x4 High, but it would NOT go into 4x4 Low, then later on in the day. Nothing, wouldn't go into 4x4 High or Low no matter what i tried, and the dash 4x4 lights still flash me as i drive. Also the 'binding/wind-up' has decipated alot since plugging it back in. Its still there but only really noticeable when turning, and again seems to be fine after a short drive.

This is a seriously annoying issue, granted i could drive all day in 2wd more and it would be fine. But that kinda defeats the point of owning a 4x4.

I have looked alot on the forums, but haven't really found anything relating to the varying issues im having. Any help would be MUCH! Appreciated

Thanks, Rick


Ps, Im in Australia if that makes any difference

 

[adamsbro2]

couple questions.. by binding do you mean that when turning while in 4x4 it would kinda jump?? if so were you on dry ground?? Next is yours an auto 4x4, 4wd high, and 4 low? or just 4x4 and 4 low?

 

[KPT]

First off the shift motor has nothing to do with four wheel drive. It only changes the t-case between high and low range.

The 4405 is not a particularly strong transfer case, I would be surprised if it didn't have internal issues at this age.

If it was mine I would start by taking the shift motor off and seeing if you could manually turn the selector to low and verifying the case is actually in low. You won't get 4x4 doing this but it would help to rule out the shift fork and shift rail bores.

While its off clean the metal contacts. These tell the GEM what position the shift motor is in, this may be causing the flashing lights.

I would also do the brown wire mod so you could force the clutch pack to lock. Verify the front driveshaft is powered. You have a vacuum disconnect in the front axle, you may have to put the truck on jackstands and verify the driveshaft turns. If there is an issue with the disconnect you're not going to have power to the halfshafts.

 

[Rickwhite1991]

Yes by binding i mean jump sorta thing when turning on tarmac.

So i put the shift motor back on, mine is different to the one featured in the "shift motor rebuild" thread and the metal contact parts appear to be in a sealed plastic housing with a small 'key' that connects to the cog.

Anyway after putting it back together, i took it for a drive. And all was working, shifted into 4high and 4low no worries, low was defiantly working. Then the flashing started again took it to a local park on dirt/mud and it wouldn't go into 4x4high, or atleast the dash light didn't come on same with 4x4low. but it did go into 4x4low (could tell cause higher rpm for same speed) then after accidently stalling, once it turned back on the dash lights worked as they should again.

After i got home, i jacked the front end to check if it was engaging, and it seems to be fine. However when in 4x4high mode (didn't check low) i can only turn either wheel half a revolution before it locks completely. This might be normal idk.

So it seems to work, but dash lights dont always work, and in 4x4auto is still having binding on tarmac. The binding seems to come and go.

 

[Rickwhite1991]

So after some more testing this is what happens.

After turning the car on, it shifts into High/Low no worries, dash lights work etc. But in 4x4Auto it wind's up on tarmac until a wheel skids/skips etc.

However after this occurrence, the car runs and turns fine, without any issues. BUT! The 4x4 seems to stop working, it changes into low no worries. But no Dash lights, and no binding on tarmac (even when in 4x4high or 4x4low) Also the 6-flashing light thing starts up.

So it seems to me, correct me if im wrong. That the computer feels the wind up and go's into some 'safe mode' were i assume it just cuts power out the electromagnetic clutch and begins flashing the warning lights.

So i guess my Major issue, is upon turning the car on. The 4x4 system is "locked" on until the pressure on the drive line becomes to much and it gives way through a tyre skidding/slipping and at the same time something happens to stop the 4x4 become enabled again.

 

[Rickwhite1991]

Bump - any ideas?

 

[Rickwhite1991]

Well thanks for your input. Turned out to be Faulty Hall Effect Sensors.

 

[adamsbro2]

I'm glad you were able to figure it out! I was stumped which is why I didn't continue to reply!!

 

[slickemhoundd]

Since your issue is fixed I assumed that I can hijack this thread I am having an issue with my 4405 as to were the 4 wheel works unless its under any kind of torque load the last time I went out I was crawling on the rocks I had some people check out what was going on underneath. The conclusion was that as I was crawling the driveshaft seem as if it was skipping as if the chain with skipping teeth giving me a very distinct sound. We had also verified that the driveshaft was intact it was skipping splines it seemed as if you transfer case was giving out under load. Is it possible that you had the same affect as to where when you switched out the sensor your problem went away or is my t case shot