'98 Moutaineer 5.0 - AWD not working

[CDW6212R]

Obviously the AWD TC's are getting old enough now that we are learning of more symptoms of them wearing out. The power isn't locked to the rear shaft, we have known that. The viscous clutch is required for some kind of power transfer. The chain has to be there to drive the front shaft from the VC.

 

[Workman]

After looking at more pics of the case apart, I see that the chain should be right around the area of the fill plug. It's close enough that I should be able to feel it. When I checked it, I only felt a thin piece of metal. Hard to explain but it was shaped like this, |_|. Was maybe 3/4" wide. I can slightly move it with my finger but it was definetly attached. Looking over the pictures, I haven't seen anything like it.

Chain in the bottom of the case makes sense for the "extra" fluid. The chain should be in the lower area and I should be able to feel it through the drain hole. My plan to pull the transfer case failed when I realized I couldn't find any torqx bits.

 

[hazmat456]

anybody's suggestion could be correct, we just won't know until you pull the case apart. I don't know where a chain could sit in the bottom I think that it would really tear stuff up if it broke. if the previous owner hot rodded the truck alot they could have easily burned up the clutches in the v/c.they could have simply removed the thing because they didn't want to buy new parts.
wal-mart sells torx bits for a 3/8 drive

 

[CDW6212R]

Where did the truck come from, would the last owner have done something out of the ordinary with it? I think I might check the two ring and pinion ratios before investing too much money into it.

 

[Workman]

It came from a hillbilly in Ohio. Nothing has been modified on it, just kinda beat up. I actually never even thought about checking the ratios. Good thinking though, It would suck to get the case fixed just to find out I have different gearing front to back. I'll check that out as soon as I can.

 

[CDW6212R]

I'd check that if I thought the last owner might have been likely to do that, a truck that went off roading, or racing. He might have done that without thinking of the TC first, novices.

 

[Workman]

Since it has over 200k miles, maybe there was a failure in the front or rear diff and they just replaced with whatever fit. That sounds very possible and could cause the VC to slip until it failed. I'll check all of this when it comes time to rip and tear.

 

[pubenemy]

That definitely shouldn't be the case, many AWD owners have removed their front drive shafts for many reasons and their truck is still drivable.

Well there awd transfer case must have been in working order. I think mine is shot hence I was driving on fwd power only which tore up the front drive shaft. Now with it removed I hit the gas and go no where. And putting it back into park is like putting a vehicle still rolling into park makes that clicking noise. I wish I could just run rwd. But it looks like a transfer case is in order either anothe awd case or thw 4wd transfer case to do a swap...

 

[CDW6212R]

Well there awd transfer case must have been in working order. I think mine is shot hence I was driving on fwd power only which tore up the front drive shaft. Now with it removed I hit the gas and go no where. And putting it back into park is like putting a vehicle still rolling into park makes that clicking noise. I wish I could just run rwd. But it looks like a transfer case is in order either anothe awd case or thw 4wd transfer case to do a swap...

For that truck, while it isn't driving any shaft to be able to stop it, don't put it in park with the engine running. That can destroy the park pawl mechanism if you keep doing it. Shut off the engine before putting that into park.

 

[pubenemy]

For that truck, while it isn't driving any shaft to be able to stop it, don't put it in park with the engine running. That can destroy the park pawl mechanism if you keep doing it. Shut off the engine before putting that into park.

Yea thanks for the heads up on that I only did it once with the puzzled looked on my face as I tried to drive it after removing the front shaft and going nowhere :/ So now to either find a cheap replacement awd transfer case, attempt a rebuild, or go with a 4wd transfer case and just run in rwd for now which is all I really need. I just need something reliable to get around on the cheap. Paid $600 for the whole vehicle dont want to put $1k into a reman'd awd transfer case. Sorry to threadjack but from what Im reading bw 4404 is my awd transfer case, and bw 4406 is what I want for a 4wd transfer case and run in rwd and future upgrade to full real 4wd?
Thanks

 

[CDW6212R]

The AWD cases are either 4404 or 4403, the only key is whether it has a speed sensor in the rear. The 98-01 can use either case, but you have to have the older one with the speed sensor in it.

The 4406 is a big monster, it takes some hard work to get it in there. With the manual version you just need to cut a hole in the floor for the shifter, and get a rear shaft. The TOD version requires a shorter gas tank and a bit of wiring etc.

I've still got a spare 97 trans and AWD that I didn't use for rebuilding. I can sell the AWD but I really don't know how good it is. I bought it from Pedstang for the trans, it's supposed to only have 75k miles on it.

This thread is Workman's, he needs to decide whether he wants to try to rebuild his, or replace it.

 

[burtonbrd138]

what if this mans truck has a Brown Wire Mod in it? And all he needs to do is find the switch

 

[pubenemy]

The AWD cases are either 4404 or 4403, the only key is whether it has a speed sensor in the rear. The 98-01 can use either case, but you have to have the older one with the speed sensor in it.

The 4406 is a big monster, it takes some hard work to get it in there. With the manual version you just need to cut a hole in the floor for the shifter, and get a rear shaft. The TOD version requires a shorter gas tank and a bit of wiring etc.

I've still got a spare 97 trans and AWD that I didn't use for rebuilding. I can sell the AWD but I really don't know how good it is. I bought it from Pedstang for the trans, it's supposed to only have 75k miles on it.

This thread is Workman's, he needs to decide whether he wants to try to rebuild his, or replace it.

Ok well if hes not interested I am can contact me direct at pubenemy a t gmail my zip is 34288
Thanks!

 

[storlied]

what if this mans truck has a Brown Wire Mod in it? And all he needs to do is find the switch

The brown wire mod doesn't apply to the true AWD system since the AWD operates by itself.. there is no selectable 2wd to begin with. There's no external controls to the AWD system.

 

[Workman]

I'm going for the rebuild whenever funds permit. After some research, I would really like the 4406 but I'm also very curious to rebuild it as I have never been into a transfer case before. I may rebuild and sell it to get some money for the 4406.

Also,
pubenemy says that he lost power to the rear wheels. Would that be a symptom of a bad viscous coupling? I've done a lot of research on the VC but the only symptoms I've really seen of a bad one is where it is locked up full-time. But I'm assuming that one that will not lock, for whatever reason it may be, loses power to the front, rear, or both.

Lastly, what transfer case would come in a '95 explorer with the 4.0? I believe it said "contral-trac", or something along those lines, on the back. And would anything from this one be useful for mine? Only reason I'm asking is because my dad has one lying in his garage.

 

[rizzjc]

I don't think that transfer case would do you any good.

 

[Workman]

Yeah, I noticed after looking at it. Plus it was trashed, only worked in 4low. I was hoping I could get lucky though. Still looking forward to a rebuild soon.

 

[CDW6212R]

The V8's have a six bolt TC pattern on the trans, the V6 pattern is five bolt. Only the V8 transfer cases can work, so it's either the small AWD, or a large TC from a full sized truck.

 

[gijoecam]

Holy cow!! I go away for two weeks, and this place goes nuts! Let me try and straighten some things out...

I'm just really wondering about the viscious coupler. How exactly does it work and would it cause power loss to the rear wheels?

Check out the thread in the Trans and T-cases forum on this site. There's a thread titled "School me (and you) about Viscous Couplings". That may clear up some of the confusion.

My understanding of it is the rear wheels are directly connected through the tcase to the tranny, the vicious coupling senses slip in the rear wheels and puts power to the front.. it's a self contained unit.. which contains plates interlaced with each other.. with a fluid that stays liquidy when there's no difference mixing it around.. but when there's slip.. and the plates start moving differently from each other the liquid solidifys locking the front to the rear. Kinda a messed up description, but it gives ya a general idea.. and if I'm wrong, feel free to correct me anyone.

Incorrect. I could try to explain it, but the afore-mentioned thread with its pictures makes more sense. I can see it in my head, but putting it into words is difficult... Basically, in the AWD case, power is applied to the planetary gears, which proportions the torque front and rear. The VC limits the maximum slippage that can occur between the two outputs. It's not a direct drive like the 44-05.

Now that I look at it, looks like your chain broke. From what im seeing the rear drive shaft is driven straight off of the transmission while the front drive shaft is driven off of the chain.

That's where I'd put my money...

A couple observations... First, there's obviously no mechanical link between the front and rear outputs. That clearly points at a t-case problem. Now, if it was solely a broken chain, the truck would roll down a hill when placed in park, just like if you took the front driveshaft out of a V-8 Ex with a working t-case. That leads me to believe that the VC is also shot (i.e. the VC probably failed in the locked condition, then the chain broke from the added stress).

The only thing that's going to tell us what the problem is will be to drop and split the case. Unless you want to order a complete case, there's no telling what the problem is until you get to that point. Good luck!

 

[410Fortune]

The AWD cases are either 4404 or 4403, the only key is whether it has a speed sensor in the rear. The 98-01 can use either case, but you have to have the older one with the speed sensor in it

What about the 96 trucks? we have a different front d shaft yoke, not the CV style, is there a different part number for the 96 AWD case with the real U joint style front flange?

LOL you would think Ford would have learned after making a CV rear d shaft for the BII that was nothing but headaches... the fix? convert back to the 84-86 style metal shaft