Possible clutch problem 92 explorer XL

[BigPapiBrady]

I will have to try that. It's sitting in the back of my rig now. I can spin the input end of it and it doesn't spin the output shalf right now. I'll try manually shifting it and see if it changes anything.
If the t case is bad could that explain why I loss power to the wheels? I was thinking that but it still doesn't explain why I was able to shift through all my gears while the engine is running without pressing on the clutch.

 

[the_don]

If your getting rotation in and out if the trans in all gears it would have to be. the only thing i could think of is without any resistance on the trans output the syncros are working overtime.

 

[BigPapiBrady]

Don,
Thanks for the help. I have taken off the top of the tranny and shifted through the gears. The input shaft turns the output shaft in every gear. So now I'm looking at the t case. Once again caught up with work and my other side projects but I'm dedicated to fixing this.
Once I diagnose the t case problem, if the shaft doesn't turn when I turn the input shaft what would I have to do? Would it be easy as in just replacing the shifting piece? Or would I have to dig deeper into the t case and see if something mechanical is actually broken?

 

[djleatherb15]

Something like this happened to me. I was at a stop sign in my other car (98 Honda Accord), all of the sudden I couldn't go. Without notice something went and I couldn't go anywhere. It turned out that it was the slave cylinder. I'm not to sure about what the clutch system is like in the Explorer but you could check the slave cylinder and get a new one and it might fix the problem.

 

[the_don]

ive never been inside the t-case, but being cheap enough on craigs and at wrecking yards i would just replace it.

 

[2stroke]

I agree, get a used one from a junk yard. Probably cheaper than it is to fix it, and as simple as just bolting it up.

 

[BigPapiBrady]

True, thanks guys.
Well I took everything off and cracked open the t case and found everything from handfuls of metal shavings to a melted plastic fork for the 4wd engagement. So I believe I found my problem. Still skeptical on whether this is my problem for 2wd not working. But I spun the input shaft and the output shaft for the driveline only spun about half the time. Lots on catching and grinning noises.
I will upload some pics as soon as I learn how to. Any help with that would be appreciated.
It appears the "guy" I bought it from didn't believe in maintenance. Using that guy term lightly seeing as I had to clean the busted crack pipes out of it.
Very interesting pics for you guys though. If anybody else is having this issue and needs some help I have become very experienced in working on the bw1354 transfer case.

Djleatherb15: I thought it was something with the clutch first too. But made the mistake of taking everything off first before testing. I reassembled it and tested the clutch but both the cylinders are working. The clutch fingers we're releasing and clutch seemed fully operational.

 

[2stroke]

What I want to know is how that happened by just shifting into first. You said there was no warning, no growling or clicking at all. I wonder if it might have been stuck in 4x4 the whole time without you knowing it?

 

[BigPapiBrady]

By what I have seen from digging the scraps out of this thing I believe that that could be a possibility. Thankfully the chain for the 4wd and all the gears are ok. The planetary gear and sun gears are ok so that was my worry because those alone are a few hundred bucks! I'm planning on just buying a t case from a junk yard and mix and match the best parts and just rebuild the whole thing.
Still trying to figure out how to get photos uploaded but once I do I will upload all the ones I have to help anybody else who is having problems with this.

 

[2stroke]

Upload to photobucket, its easier if you register an account. Then click on your picture under library, and on the right side is four links. Simply left click the one that says IMG and it will automatically copy it. Then just paste the link in your post, and the picture will come up.