97 Exp XLT - binding/grinding and 4WD lights flashing on and off

[Andy Corwin]

I have a 97 Exp 4wd 4.0L V6 SOHC. Lately I have been experiencing a grinding and general binding when I make a sharp turn, and I hear a thumping sound. I also notice that my 4WD Hi and Lo lights on the right side of the dash flash on and off. I took it to a garage up the street but he said I need to take it to a transmission shop, that it was something in the transfer case and it was trying to go in and out of 4WD? I'm not a mechanic and I know just enough to get myself in trouble. ? This vehicle is 25 years old and I only use it to go to the beach on the weekends (I don't drive it on the sand) and to run errands to Home Depot, Lowes, and such. I've driven it less than 2000 miles a year for the past 3 years. I really like this vehicle but I don't want to throw tons of money at it. I'm going to take it to a transmission shop tomorrow, but based on what I have said here, can someone tell me what I'm possibly/probably looking at?

Thanks in advance for any info and advice.

 

[XLTrunner]

I would prepare yourself for news that the transfer case is in need of a rebuild. Had the same problem even though I had never touched the dash switch in the previous 50K miles that I owned it. Truck had 153K miles when it started grinding when turning. Tried changing the fluid, installed a new shift motor and removed/cleaned the (2) Halls sensors...all to no avail. Good luck.

 

[Andy Corwin]

I would prepare yourself for news that the transfer case is in need of a rebuild. Had the same problem even though I had never touched the dash switch in the previous 50K miles that I owned it. Truck had 153K miles when it started grinding when turning. Tried changing the fluid, installed a new shift motor and removed/cleaned the (2) Halls sensors...all to no avail. Good luck.

Thanks. This truck has 165K on it. What do you think is a reasonable price for the transfer case rebuild?

 

[XLTrunner]

My local independent tranny shop charged me around $850...but, that was about 7 yrs ago. I wasn't interested in a used one from the JY as I figured that would have been a total crap shoot.

 

[Andy Corwin]

My local independent tranny shop charged me around $850...but, that was about 7 yrs ago. I wasn't interested in a used one from the JY as I figured that would have been a total crap shoot.

Thanks for the input.

 

[C420sailor]

They’re not hard to change. I’d take the JY crapshoot, but that’s just me. I’ve got 330k on my 4405 but I don’t off-road. If you get a rebuild, make sure the guy knows what he is doing and has a solid warranty on his work. Some portions of the case can wallow out, and a poor rebuilder may not have this repaired…and your ‘rebuilt’ case won’t last a year

 

[Fix4Dirt]

They’re not hard to change. I’d take the JY crapshoot, but that’s just me. I’ve got 330k on my 4405 but I don’t off-road. If you get a rebuild, make sure the guy knows what he is doing and has a solid warranty on his work. Some portions of the case can wallow out, and a poor rebuilder may not have this repaired…and your ‘rebuilt’ case won’t last a year

^^^good words imo id find a good rebuilder and then take your case or anJY case to them. the person you get can make or break everything imo. i do have 323k (probably more odo stops when hot) on my stock 4405 and no issues yet

 

[410Fortune]

your 97 control trac (torque on demand) transfer case is likely kaput
There are nylon guides inside that come apart and then the t case is bad and needs rebuild

Now your 97 also has a speed sensor in the back portion of the t case
So you CANNOT just swap it out for a 98-01 control trac t case from a wrecker/junk yard, that is unless you have the ability to take the two cases apart and install the back half of your 97 case onto a good working 98-01 case.
(This takes about 20-30 minutes for me to do, it is not that difficult))

FAR cheaper then $850 for a rebuild.
I have kept many 96-97 trucks (with the rear mounted speed sensor) on the road this way

 

[drdoom]

First I would confirm all four tires match.