'96 Explorer XL with control trac

[travpeterson]

I have an issue with the 4x4. It clunks very loudly, and repeatedly under acceleration, and first starting out. I am not sure if it is the transfer case or the front diff. If I am driving on an icy/snow covered road at above 50 kph, the noise is not there or at least it is not noticeable. I understand that a little noise is to be expected, but I think this noise is outrageous. It almost seems like it is slipping and the 4x4 is not working properly. I am thinking that the chain or one of the gears may be worn out or broken in the transfer case or it is not engaging fully. I try not to use it if possible, but there are times where I need it and I can barely get out of minor situations. Has anyone had similar problems or any ideas on where to look and check. Thanks-Travis

 

[Glacier991]

Let me start by disclaiming any expertise on the 96 control trac.

I have one apart and have been reading on it. From everything I know, this transfer case (4405) suffers from the fact the shaft for the fork guides in the case... and it eventually ovals where the shaft ends go, not being designed as a bearing surface. This seems to cause all kinds of problems.

In spite of knowing intimately what the guts look like, I cannot offer a diagnosis by symptom for you, other than to guess your TC is on its last legs. I am sure others may have more intelligent responses. I'm sorry I am not more help for you.

[Check out the 4405 Transfer case Rebuild Diary in the stickies at the top of this forum]

 

[Wrench]

Well trav, I have a 97 version (4405 TC) and it is dead silent at all times. Check the transfer case fluid for metal count but I have a feeling you have either a slack chain or the dreaded shift fork/clutch . It does not sound like the front driveshaft joint coming out of the TC but be aware that this also can be an issue.

 

[Glacier991]

I wondered about chain issues but was not smart enough to offer that with any experience or conviction. I am learning. This kid is way low on the learning curve with these TC's... but trying to come up fast.... Nothing like building a few to understand. (2 apart on bench as we speak) 97 an 98.