Making a grinding noise

[expHendrix47]

When my truck rolls very very slowly it makes a grininding noise which sounds like it's coming from the front, but it stops doing it when you put it in neutral...what could that be?

 

[Pika351w]

Any help with this

Hello, brand new to this forum but I was wondering if anyone had any advice for this problem. Our 97 explorer sounds like it is doing the same thing. Truck runs fine when accelerating but as you are slowing down it starts making a grinding noise at about 1500 RPMs it will quit once it gets past 1000 rpms as you stop or it will quit if you put it in nuetral. Any advice?

Thanks,
Matt

 

[Pika351w]

Update, took the Ex to local Ford Dealership and had a tech ride along with me. He thinks that it's coming from the rear transfer case. I am hunting around for a shop. When we figure it out, I'll post an update.

Thanks,
Matt

 

[general x]

coming from the rear of the transfer case or coming from a rear transfer case? Theres only one transfer case and its in the middle of the truck. Rear diff?

 

[Pika351w]

My bad, Rear of the transfer case. It sounds like it's coming from th middle of the truck. The tech thought it was probably a bad chain. It sounds like it could be a chain or the gears, almost as if there is a few teeth missing and something isn't catching. Like when the starter hits a dead spot in the flywheel. Just got of the phone with a shop that rebuilds transfer cases and all he could tell me was it could be between $550 and $950 to fix and that is if I take it off and bring it in to him.

What do you guys think?

 

[Cali' Explorer]

It is possible. The chain in the Transfer Case stretches over time and wears. It can get so bad that it will actually damage the Transfer Case. I don't know after how many miles you need to replace the chain but from what I understand, you can do it for relatively little money (compared to paying a shop for it).

You can see some more information on it at the following link:
http://www.dw-zone.com/transfercase/transfer_case.asp

Also, a better way to ensure where the problem is would be to get it up on a rack (or on 4 jackstands, BE CAREFUL) and put it in drive while all 4 wheels are off the ground... At this slow speed you should be able to get under the vehicle and hear exactly where the problem is coming from. If you took it to Ford, you may want to have them do this and show you, no reason having the Transfer Case rebuilt/chain replaced if its not the problem.

 

[Pika351w]

Hey Steve, thanks for the link. I'm going to take it to one more guy, he is a 4x4 specialist, and get his opinion. I would like to tear into the transfer case myself so I wouldn't have to pay anyone to do it, but I don't know if the missus will let me do that. I'm going to take a look at the link and see what I can learn.

Thanks again. Will update.
Matt

 

[Cali' Explorer]

No problem. Also, just search for "4404" transfer case, or "4404" borg warner or something along those lines on Yahoo. I found a bunch of sites talking about these transfer cases (our Transfer Case is the Borg Warner 4404 in case you didn't know). Good lukck =)

 

[Cali' Explorer]

Matt, just wondering what you're outcome was. The funny thing is, I think my Transfer Case just went.

I was driving home from a Birthday and about 20 minutes from home I started noticing sever vibration from the front end (At least severe for my X).

As I pulled off the freeway and slowed down I started hearing a mettalic crunching/dragging sound. As I accellerated, the noise more or less dissapeared unless I really floored it, but as I decellerated, it started making the nasty metal sounds again.

I pulled off the road about 1 mile from home (fearing I was going to lose a drive shaft or something) and climbed under the car and checked the front drive shaft (the area the noise was coming from). I wiggled it every direction and it looked fine, but if I turned it, I noticed it moved about 1/8 of a turn either direciton with a lound "Clank" sound at either end. So, I figure its just the Chain going.

I have about 82K on the Explorer, but luckily have an Extended Service Plan that still has around 3K left on it and the Transfer Case and all Drivetrain/Driveline is covered for a $100.00 deductible per incident, so back to the Dealership the X goes this next week. Although, I think its going to a different dealership this time if possible, although the closest one is only 1/2 mile away, while the next closest is 10 miles on the freeway, so I may just be SOL.

Wish me luck as well =).

 

[expHendrix47]

So i'm thinking hte noise is the chain then?...how much is a chain to replace?...there anyone who has step by step instructions of how to get the transfer case off, dissassembled and back together properly?...i don't kno much about working on cars, but i'd rather do it myself if it's not to hard of a job then paying out the ass to have it fixed if it's a pretty simple job...

 

[Cali' Explorer]

Hendrix, I've heard a couple of guys mention on and off that its about $500 - $600 to have it rebuild by a shop. To do it yourself is about $180 in parts and you have to remove the front and back drive shaft, the Transfer Case cover and the disconnect the Transfer Case from the Frame and Transmission before you can even get at the Transfer Case.

If you have a fair compliment of home shop tools, you should be able to do it ok, its probably a 6 hour job for someone who knows nothing about it. Check the link earlier in this Post for more information about this rebuild, although I would say this is not for the faint of heart, so if you do it yourself, plan to not have it for a couple of days just in case.

Just my .02.

 

[Cali' Explorer]

Ohh, also, just some more input here. THe weird thing about the Chain is I have looked through all the Documents I can find and none of them mention anything about replacing/servicing the Transfer Case (Shy of removing and replacing the fluid).

Is there a certain interval that you are supposed to tear the Transfer Case apart and rebuild it?