AWD Transfer Case Problem

[masospaghetti]

I doubt the chain is loose enough to skip teeth, there are guides in there to prevent that (A loose chain at worst would cause a clunking or jerking sensation).

At 240k miles with fluid like that, pretty high chance your transfer case needs service. A failing VC can create a popping noise but then again, the VC seems to at least be somewhat functional because the truck creeps. I don't think there's any definitive way to diagnose the VC.

Are you sure the driveshaft CV is good? Maybe that's the cause of the noise?

 

[JakePSD]

Both mine and her trucks have the double cardan type drive shaft, there is no CV on it. I know its something in the case anyway because when I was tightening the driveshaft bolts is when I first noticed it. I would put pressure on the wrench, then it would pop and jerk a few degrees where it would stop until I put more pressure again.

 

[SoNic67]

That's a CV (front propeller shaft to the AWD Transfer Case - center differential).

If you have anything else, you have a 4x4. Or it was retrofitted by somebody with a cardan.
I think '96 came with that:
http://www.explorerforum.com/forums/showthread.php?t=222959

 

[Turdle]

That's a CV (front propeller shaft to the AWD Transfer Case - center differential).

If you have anything else, you have a 4x4.

96-97 is different. look it up.

 

[SoNic67]

Gavin researched and found out that 97 has CV... OP info says 97...

Gavin even posted this:

Jeremy, although you did not purchase this assembly from us I can tell you that we have quit offering this shaft and now offer them with the CV joint and call them an 8305CV. The 5.0L Explorers drive line system run at a different angle then the 4.0L Explorers. Although we did have some success with the U-Joint conversion we received a higher then acceptable return rate for the 8305C and quit making them a year ago.

 

[Turdle]

Gavin researched and found out that 97 has CV... OP info says 97...

Gavin even posted this:

Only going by what I have personally seen. Not what others have said they saw. If the OP says he has a v8 with a DC I would say you should believe him. yes?

 

[Turdle]

late 96-early 97 v8 awd front drive shaft, ccording to rockauto.com

and, in fact, this is the 27 13/16" version

 

[masospaghetti]

Be careful, the parts houses (including rockauto) show a single cardan front shaft to replace the factory double cardan front shaft. I don't see how this would work without extreme vibration.

The double cardan shaft you posted is for early V6 models. The V8 models use a 4-bolt flange at the transfer case side.

The switch from double-cardan to CV was done sometime in the 97 model year. If the OP says he has a double-cardan, I believe him.

 

[SoNic67]

Didn't say that I don't believe him, just that I didn't think is correct for a '97 (based on my readings switch was in the '96).
Maybe I am wrong, only somebody from Ford factory that build them can be 100% sure. If they didn't retire by now.

 

[JakePSD]

I can tell you both mine and my girlfriends trucks use a double cardan drive shaft. I've been under them enough times to know. Both of ours are early build 97's. Mine is 5/96 and hers is 7/96, apparently before the cutoff day, whatever that is. Maybe post cutoff day 7/96 up have the CV with a 6 bolt flange, but ours are the DC 4 bolt. Our gauge clusters are different too. Our gauge clusters are actually the same ones used in the 96 exploders.

Oddly enough I found that Super Duty trucks use the same tcase end drive shaft bolts, probably the axle end too, didn't try, for the 4 bolt version at least. The only difference is on the SD bolts there is a little bit of extra unthreaded shank at the tip. I know this because I have a Super Duty, and have lots of extra bolts for those trucks laying around. When I got her drive shaft obviously I needed bolts since those weren't included, and was not about to pay $5 per bolt at ford. I tried the SD bolts and they worked perfect. But if you've been following this thread, you'd know that I now have spare bolts once again.