95 xlt 4X4 Transfer Case problem?

[beaker]

The wife has a 95 xlt 4x4 4.0L automatic 160k miles.

We had some ice a couple of weeks ago and we go out to run some errands I put it in 4 high and the 4x4 light on the dash takes longer than normal to turn on but does. 4 wheel drive is working as we are crusing around town taking care of business.

We pull in to costco parking lot and the roads are starting to melt and the parking lot is dry so I switch it back to 2wd. The light does not shut off and it does not seem to have come out of 4wd.

I park go into costco. when we get back in the car and start it 4wd light is off and as i back up there is a lage clunk and I can tell 4wd is disengaged.

as Im driving I notice a loud hum (gears spinning or like a open lug tire howling down the road) seems to come and go.

week later the wife complains that the care is studdering like its trying to shift and occasionly makes a clunk clunk sound.

I drove it and noticed the problem. happens around 35-45 as I let of the accelarator its clunks pauses clunks pauses clunks pauses. Till the speed gets to around 30.

The transmission seems to shift fine and at the approiate times.

It seems like the front wheels are not 100% disingaged. I looked through my worthless manual but it provided 0 troubleshooting for the transfer case. Im thinking the motor assembly, shift position sensor or the GEM.

has anyone here experienced this? What steps can I take to troubleshoot this problem? Should I be driving the vehicle? Any help would be greatly appreciated.

PS I also tried taking it in and out of 4wd high and low and 2wd. It takes awhile for it to engange and the light to come on and same for disengaging and the light turing off.

 

[TPLYNCH]

You may just need to clean the shift motor. Search for the Shift Motor Rebuild thread by Brain. Also, a quickie possible fix, especially if you think it is still in 4x4 is to disconnect the battery for ~30 minutes to reset the computer. This sometimes helps the motor "remember" what position it is supposed to be in.

 

[beaker]

TPLYNCH thanks for the reply. I will try the old "disconnect the battery" trick.

If that doesnt do the trick Ill yank the motor and inspect it.

Thanks Again

 

[beaker]

well I unhoked the battery... then took the x out for a test drive.. the clunks have gone away (for now) but the gear noise/hum is still present.

I found a big gravel parking lot and put it into 4H it would engage after a short time and seemed to come out of 4h with no problem. I tried to get it to go into 4L but I dont think it ever did. The 4L light on the dash never came on.

Anyone think I should yank the shift motor and go through it? I maybe have a need for 4H 2-3 times a year... and this year is looking quite mild. Should we be driving this vehicle or can I wait a few days to tear the shift motor down?

 

[TPLYNCH]

As long as you're not getting binding while driving it in 2wd, should be fine. Also, check the transfer case fluid level. The hum could be caused by that. Worst case scenario is the shift fork? in the t/f case is shot, but that's a final resort check.....