96 explorer 4wd issue

[slickemhoundd]

As of lately when in 4lo (dont use auto) ive been getting this crazy clank clank when under as much as half acceleration. 4wheel still works but sticking my head out of the window it sounds like its coming from the tcase but cant be positive. Its driving me crazy especially with a harsh winter ahead. Any input is much appriciated, this is my fiances dd on 33s so im anxious to straighten this out

 

[PopRichie77]

Sounds like TC problem, chain may be jumping over the teeth. Why 4 LOW? Does it work ok in 4 High? Have you been driving in 4X4 on dry roads? Are all 4 tires the same size?

 

[slickemhoundd]

I have the 2hi 4auto 4lo selections, and the only time id use auto is in snow or a unpredictable trail. Other than that ill creep through a mud hole in 4lo or blast in 2hi. Ive never used 4wheel on a surface that wont break under the tires and from 255s to 31s to 33s all four have matched.

 

[slickemhoundd]

if it is indeed jumping teeth it would be a stretched chain, not missing teeth correct? assuming if teeth were missing theyd be tearing the t-case apart. ive looked into rebuild kits but have only come up with basically seal and bearing kits referred to as master kits, ida figured a master kit would be for complete rebuild.

 

[drdoom]

There are kits available that contain the parts that commonly fail...worm gear, shift fork, range collar, input shaft, pump, etc.
http://www.riversidegear.com/transfer-cases-and-parts/ford-transfer-case-parts/4405-borg---warner-transfer-case-explorer---mountaineer/4405-borg---warner-major-hard-part-kit--explorer---mountaineer-1995---2001.html

That case is easy to remove and work on, you should pull it and have a look see.

 

[slickemhoundd]

I had my boss pop his head under the truck as i power braked in gravel in 4lo and he said it seemed as if something in the differential was skipping, making the popping noise.

 

[PopRichie77]

When braking hard in gravel the ABS will jump back an forth from the wheel that is sliding. This does make noise.
You originally said the problem happened under acceleration.

 

[drdoom]

Does that model have the disconnect system in the front differential?

 

[slickemhoundd]

It does happen under acceleration, anything more intense than a easy launch. I was only powerbraking so i didnt squash my boss. As far as a disconnect im not sure what your reddering to. Its a vacuum actuated axle if thats what you mean.

 

[mr_valingo]

i had a crazy popping/binding sound coming from what seemed to be right under my feet. at first it was only occasional like when first starting in 4lo or 4hi (brown wire mod) then was consistant under load. turned out to be a stretched chain in the case. manual t-case solved my problems in an afternoon

 

[slickemhoundd]

say it is a stretched chain, i havent found a complete overhaul kit for it. ive got an identical ex at my shop being scrapped so i was gonna yank the t case and rebuild.