97 Explorer 4wd troubles!

[EXSPORT97]

Hello everyone, newbie to the forum and like what I see so far. Ok here is what is going on... I bought my 97 Ex sport 4.0 sohc 4wd knowing the 4wd did not work. After doing a lot of the troubleshooting and tests I've read in previous threads, I came to the conclusion it was something internal in the TC. In 4hi and 4lo it would only drive the rear wheels, no flashing 4wd lights, as they were working properly with mode change. I can hear the shift motor changing also, and would drive in 2lo. Even on jack stands the front driveshaft nor the wheels would turn only rear wheel drive.

Pulled the TC and tore it down and the plastic ring was in a dozen pieces and the clutches only had one side of material. So I replaced the clutch pack, inspected all the other areas. Put it back in and still not wanting engage until I would give it some gas pedal. You could hear the clutch locking up when I would gas it in 4hi and 4lo, but would only pull the rears idling in drive on jack stands..

Sorry for the novel, just trying to give somebody the best info I can.
Any help would be appreciated!!!!

Thanks,
Sean

 

[EXSPORT97]

Anybody??

 

[Beargap]

Do the front wheels turn when you select 4wd-Hi or 4wd-Lo? Either of these settings should lock the clutch pack on in the transfer case. Even in 4wd-Auto the clutch pack should engage 10% of the time, so the wheels should be turning if unloaded.

 

[EXSPORT97]

They will turn in 4hi and 4lo only after I give it some gas, not idling in drive.

 

[EXSPORT97]

Voltage on the brown wire at the TC coil was 6.4volts, with 4hi selected and in park, engine running.

 

[Beargap]

Voltage on the brown wire at the TC coil was 6.4volts, with 4hi selected and in park, engine running.

That sounds like it could be the problem. Is your alternator working OK?

 

[EXSPORT97]

Alt seems to be working fine, I will check the voltage and let you know. I've thought about depinning the brown wire from the harness at the TC motor and running 12volts from the battery to the brown wire to see if it changes.

Thank you for the replies.

 

[EXSPORT97]

14.35 volts is what the Alt is putting out.

 

[drdoom]

Around 6V is full duty cycle aka 4high or 4low. Zero duty is about 0.6V.

 

[EXSPORT97]

So it sounds like the electromagnet is toast???

 

[drdoom]

I don't know, but the voltage is correct, everything works fine, why is it toast?

 

[EXSPORT97]

Not sure.... Going to hook it up and pull the PID's off the GEM.