T-case rebuld problems

[tweeeeka]

T-case rebuild problems

My 97 Explorer sport 4.0 SOHC control trac with what I believe is a 4405 tcase (shift pattern auto-4x4hi-4x4lo)
The t-case started making noise when coasting and downshifting (a loud ZZZZ noise). Took it in to the Ford dealer and they rebuilt the t-case. Now it's making the exact same noise again.
And now it occasionally violently shakes. The shaking can be stopped by turning the knob to 4x4hi.

The dealer can't get it to make the noise as its an occasional problem. Here is the list of parts they used to rebuild it:
F77Z-7100-AA GR-TRAN 979765
F2TZ-7A398-A PLANET 470167
E3TZ-7D063-A GEAR AS 142668
F0TZ-7B214-A FLNG AS 864129
F3TZ-7B215-A SE-TRAN 864130
E9TZ-7086-A GSKT-TR 120478
F7AZ-19554-CA SEALER 359023
1L2Z-7F293-BA SENSOR 509037

Can anyone see anything they may have overlooked? Took the truck hunting this weekend and used 4x4 hi and occasionally 4x4lo with not problems. Drove 100miles of really twisty road and 60mi highway with no noise. The truck tends to make the noise after it sits for a couple of days.

Thanks

 

[Billy177]

drain the fluid and see what comes out

 

[tweeeeka]

Gonna drain the fluid this weekend. Maybe the shift motor could be the problem?

 

[cjbarron5]

what kind of noise?????????????and when does it occur after sitting for a couple of days??????? does it go into "neutral" when it makes this noise????????

 

[tweeeeka]

\
...The t-case started making noise when coasting and downshifting (a loud ZZZZ noise). Took it in to the Ford dealer and they rebuilt the t-case. Now it's making the exact same noise again.
And now it occasionally violently shakes. The shaking can be stopped by turning the knob to 4x4hi...

The "zzzz" noise goes away if you accelerate or shift the tranny into nuetral. The power delivery is unaffected. Hit the gas and the truck accelerates. The problems usually occur above 40mph.

 

[cjbarron5]

take it back to ford they messed it up mine did almost the same thing the t case needs some attention

 

[tweeeeka]

Took it back twice. They can't get it to make the noise. Hasn't made any noise since my first post (9-09-04)

 

[cjbarron5]

hmmm sounds like you gotta sit and wait for it to become more prevelent then get it back to ford