Help with VERY strange 4wd prob...

[scotts97eb]

Hi,
I've got a '97 4.0 SOHC, EB, (Control Trac AWD? The button selections are "Auto", "4wd High", "4wd Low"). VERY strange things are happening with my 4wd system. If anyone has had anything like this happen to them, I would really appreciate hearing about it - I'm dreading going into a repair shop with such an ambiguous sounding problem... I should preclude that I just had my transfer case fluid changed about 3 weeks ago, and I've never had any symptoms like this before, and nothing up until a couple days ago. Here are the symptoms:

1) Two days ago, I noticed that after taking my foot off of the gas and coasting up to a stoplight, both the "4wd" and "Low" lights in the dash blinked on and off a couple of times. This has happened more and more over the past two days. When this happens, there are no other symptoms. Yesterday it was sometimes happening while coasting (releasing the accelerator pedal) on the highway.

2) About 4 times now, after starting the engine and starting to drive away, the transfer case acts like it is locked in 4wd - you know that resistive feeling when doing a tight turn on dry pavement - and then suddenly there's a "clunk" (noise and feel), and it goes back to normal. It's like it's starting out locked in 4wd (and the switch is on Auto, and the 4wd dash lights aren't on), and then after a few seconds it disengages.

3) Just this morning, after arriving at work (and having both of the above problems happen along the way), I pulled into a parking spot, put the transmission in Park, and turned the knob to "4wd Low) - no dash light came on. Then tried "4wd High" - still no dash light (or typical noise that the auto locks make when engaging). Turned the engine off, then back on again, repeated the procedure, and it worked fine... Very strange...

I'm going to check my transfer fluid level when I get home tonight, but if anyone has had this sort of behavior, your help would be MOST appreciated. Thanks,
-Scott

 

[Michigander]

this is a very common problem. Run a search for "flashing 4wd" or something like that and you will get a lot of info.

I had this problem too. I ended up getting my rubber mallet, crawled under the car and hit the TC where it bolts to the front drivetrain. Aparently our TC becomes missalligned a lot, so this kind of shakes it free. That worked for me, but it hasn't for others.

 

[TarHeel085]

Michigander

hey nice X, how much lift do you actually have total, also what kind of shocks you run on that thing? i mights have to bust out the mallet, mines actin pretty gay lately. when i put mine in 4L an rolled down my driveway then stopped, my front TC knocked like crazy. sound like the damn axle broke.

 

[Michigander]

Thanks... I have about 3.5-4" of lift all around. All of those pictures were before the 2" body lift though (I'll add the newer ones in about 20 minutes). I still haven't gotten and good shots since my lift. Right now I have stock shocks. It is very hard to find a company with shocks for a lifted 95+. I've heard Old Man Emu makes shocks for 2" of lift, but they are pricey. New shocks was one of my next scheduled mods, but I just broke the flywheel on my tranny, so it's in the shop ($450).

anywho... go beat the heck out of the TC with a RUBBER mallet and it will most likely fix it... if not, take it to the dealer

 

[Robert]

When you check to make sure you have fluid in your transfer case, also make sure it is red transmission fluid. The transfer case calls for Mercon ATF.

 

[scotts97eb]

Thanks.

Thanks for the info - I would never have guessed that my solution might be "hit it with a hammer", but what the heck, I'll give it a whack... (I'll check for ATF fluid too). It's not very comforting to hear that this is a problem that will probably re-occur. Did you guys that have had this problem, also encounter all of the symptoms that I mentioned as well? Has anyone found a permanent cure for the missalignment issue (other than torching/selling the vehicle)?

I did check the FAQ, did searches "Under the Hood" for a few different things including "4wd problem", and even did searches on Google, before I posted. Didn't see anything that resembled it, but now I'll try "4wd flashing", and see what I get.

-S

 

[Michigander]

Actually... I only had this problem once... and it hasn't came back.

I had the exact symptoms that you described

 

[yob_yeknom]

Just a note on problem #3. The reason nothing happened when you tried to go to 4 low is because the transmission has to be in NEUTRAL with the brake pedal fully depressed. It checks to make sure both of those are done, and if not, it will not allow the shift into 4 low.
On another note, having had the lights flash on your way to work, the 4wd computer knew it had a problem and that also causes it to not allow the shift. Turning the engine off the restarting it reset everything and allowed it to be able to shift again.

 

[scotts97eb]

update - still no luck...

Last night I checked the TC fluid - red ATF, full. I banged on the electric motor housing a little, and I disconnected the battery for about 15 minutes - still no luck. The problem of it starting out locked in 4wd (High I think) now seems almost worse. Takes a few minutes now before it finally releases (every time with a loud "clunk" and a sudden jerk in the steering wheel... Every time I've taken in to my dealer, it's a minimum of $200 worth of diagnosis - I'm thinking of trying the "R&R" method of diagnosis (Remove and Replace), by trying replacement of the two TC sensors myself... Sounds like that totals less than $200.

Maybe I'll also try removing the electric shift motor, cleaning it, and putting it back on - that's free... (but from what I could tell from searching on this topic, seems to be more related to the older Explorers than the newer ones).

PS - John: Thanks, I actually did have my foot on the brake, and I tried it both in Park and Neutral.

Thanks all,
-Scott

 

[TPLYNCH]

It could be a problem with your GEM module. That controls the 4x4 functions (as well as most other electrical functions). Have you notice any other strange things happening with other accessories? The GEM may need to be reprogrammed or replaced.

 

[scotts97eb]

No other strange things...

 

[mountaineerman]

I just had my 99 Mountaineer in to the dealer for the same problem. They charged me $65 to reprogram the gem module. So far so good.

 

[01EB5.0]

Hey guys. I know you have the full time 4WD AUTO. I wonder what happens if you pop out thge radio and just disconnect the wires from your 4WD selector switch? It may disable the entire 4WD system and then you can drive it like a 2WD truck until the weather demands you get it fixed. Thatway you might avoid any damage to the front drivetrain. I am not sure if it'll work for you cause my 95 has a 2WD, 4WD AUTO, and 4WD LOW setting.
Good luck to all!
-Travis

 

[scotts97eb]

UPDATE:

Problem has been solved - I should have just tried that R&R diagnosis that I mentioned. I took it to the dealer yesterday (my original appt was actually just to get the Firestone tires replaced - 16" EB wheels, which weren't covered in the initial recal, but then Ford later recalled).

The mechanic traced the code to the Front TC Shaft Speed Sensor - part # 1L2Z-7F293-BA, part cost $39.00. He also said the battery wasn't putting out enought cranking amps when starting, and that this probably contributed to the Sensor going bad (I'm not sure if I buy this, but they actually sold me a replacement battery for a good price). The only bummer is the $300 labor charge for diagnosis and repair (3 hours x $100/hour); but what the hell, the X is back in business, and their work is warranteed...

-S