96 X Sport 4.0L OHV 4x4 issues

[SA-Xplorer]

First of all thanks to GIjoecam for the guide to 2nd gen 4x4 trouble shooting. My Sport has the same setup as the 96 4 door. I did the test with the following results.

1. Front up on blocks, front d/shaft moves freely, front wheels move ,do not cause counter motion on each other.
2. Start vehicle, set into 4wlo, driveshaft locked and wheels counter rotating.

So take it to a hump outside and test and driving forwards it seems to work fine.

THen I try the same thing in reverse and it does not work. Rear wheels spin, no front drive. I turn it around and try forward in 4wlo again and it works fine.

So I turn it around and try in reverse but this time I apply some park brake to slow rear wheell spin, and I get a clunk! THen the front axle seems to lock up and presto, I have drive to the front axle pushing up the hump while the back wheels are spinning. It works!

So what is the clunk?

Thanks! Ralph.

 

[SA-Xplorer]

Any one?

 

[gijoecam]

First, kudos for using the search and following the troubleshooting guide first.

Could be the beginnings of a mechanical issue within the t-case, or it could be a problem with the disconnect on the front axle not fully locking in and being allowed to unlock when in reverse. If it was mine, I'd start with the little vacuum motor on the front axle because it's MUCH cheaper. But I wouldn't hold my breath...

 

[Glen4X4]

You could eliminate that issue and bolt the axle disconnect together so the axle is always active like 97+ Explorers to eliminate that being an issue but then in 2wd mode it going to be like 4auto and engage automatically since the GEM is always active on engaging the TCC.

 

[SA-Xplorer]

Thanks guys. I will as a matter of course be changing oil in TC and diffs and see itf it improves. It could well be that te 4x4 has not been used for a looooong time before I bought it. So it is entirely possible that it is sticky or something. I will go fish wiht the vAcuum motir and see if there are issues there.

Thanks again.

 

[SA-Xplorer]

I had opportunity to use the 4x4 iun some bad weather today. The 4x4 worked in high and transferred power to front as I lit up the back on some grass on a road verge. However shortly after that the 4wauto and 4wlo lights started blinking and then went off. I was not able to ascertain whether the 4x4 was working or not. It seems that this happens when it rains that the lights blink. Alfterwards, even when switched to 2wdm the lights blinked occasionally. Would I be corect in assuming that something that is not supposed to be getting wet, IS getting wet? suggestions?

Thanks

BTW. It seems I can buy a brand new 4R55E tranny from someone in south africa for equiv of about $800.00. Would this be a worthwhile buy? It includes the torque convertor and is brand new and never been in a vehicle.

 

[Verno]

Correct. What you describe is classic electrical fault. My guess is a ground wire is loose. CHeck wiring at electric motor and at 4x4 computer in left rear cargo area. Might have a leak from window getting to computer!

 

[SA-Xplorer]

thanks Verno. I will get under there this weekend