Please help! I have no clue what to fix

[jmadams007]

Ok, so i have a 2002 Ford Explorer 4wd.

I have a situation where when driving uphill or just accelerating something starts to grind. It has a brand new transmission in it so we know it isnt that as we had it inspected as that was my first throught.

Interesting thing is that If i put the car into 4x4 high it will not make the grinding noise. then if it take it back off it will grind again. It only seems to happen if I am putting a decent amount of torque on the system.

all of the bearings are new. brakes, rotors are all new. new transmission.

I changed the rear diff fluid but no help. I brought the car to the ford mechanic but somehow when he took it for a test drive he couldnt get it to grind (fml). He checked the u joints for me and they are all fine.

Is anyone else experiencing this? I dont know if it could be the rear diff pinion and spring? transfer case? i really dont know. Besides that the car runs perfect. let me know if you have any ideas. thanks!

 

[transman304]

Transfer case wear. Shift fork rod wears case and range hub will slip. Rebuild or replace TC.

 

[jmadams007]

sounds good to me. I dont mind fixing it if i know what the issue is haha. Is it worth it to have it rebuilt or is it better to just grab a new one?

 

[transman304]

That's a call you have to make. The rebuild can get pretty pricey with a rebuilt case half and other parts. Might price out a reman TC. Used is always an option but you my be getting one as bad or worse than what you have. Good luck. Keep us posted on progress.