95 Explorer Differential

[unregistered2k4]

I just retired from the Marines and was driving to Atlanta from Houston with a truck full of my possessions when my truck made a loud clunk and it started making popping/clunking noises from the rear while driving. Fortunately, I made it pretty close to Atlanta when this happened and had the car towed to Gwinnett Place Ford.

The car has 250k miles on it and is in good shape. They replaced the gear and pinion asy and overhauled the rear diff. for 1400 dollars. After picking up the truck and driving around locally, everything seemed fine. Later while driving on the highway, the speedometer died, and the O/D light started flashing. I was able to drive back to the dealership and now they state the transfer case is bad and will cost 2200 to replace.

Does anyone know of a good mechanice in NE Atlanta or any advise? At this point, the truck is not worth that much except for sentimental value.

 

[CDW6212R]

Welcome to the site, and that is a shame to hear. The rear, TC and all parts are easier to find used, so that it is better than paying for new or rebuild prices. The rear should cost about $200-$350 complete, while the TC may be as little as $150-$300 now. I would suggest a search for the TC used, know that you have to have one from before 1998. I don't know if the 95 to 97's were all the same, Ford made changes in those years on some things.

I would hunt for the BW4405(I believe it is the same number even if features are different) for 95-97 Explorers. Also find out from others here if they were identical for all three years. The labor to R&R that one TC isn't very bad at all, maybe two hours for a competent Ford tech, several for an amateur. Good luck,

 

[IZwack]

I'm thinking that its the sensor at the back of the transfer case -- this is required for the speedo to work. Pull this sensor out and go to a parts store to get a replacement.

 

[CDW6212R]

Very good thought, even better. That's a cheap test, which the dealer could have checked, or caused. Regards,

 

[IZwack]

Its been a while since I've man-handled a 97 and earlier transfer case but I think the sensor should look like this:

If you're behind the transfer case facing towards the front/engine of the vehicle, it should be at the 9 or 10 o'clock position at the rear output (where the rear driveshaft bolts up to).

 

[CDW6212R]

Isn't there a speed sensor for the front shaft also?

 

[IZwack]

Yep, but that is not used to calculate the speed -- its used only to calculate driveshaft speed difference.

 

[CDW6212R]

Right, and it wouldn't kill the speedometer. Good call to check instead of the TC.