Hi, I have a related problem. the explorer is a 1996 xlt.
We were getting this rumbling sound coming more or less from under the driver's seat, and it would disappear when we went into 4wd auto. we placed the rear end on stands and with the selector set on 2wd, we put the explorer into drive and sped up the rear tires to about 40 kph. the rumbling appear to be originating from the front driveshaft... which is spinning in 2wd!!
I did some reading here:
http://www.explorer4x4.com/controltrac_mod.htm
and here
http://www.explorerforum.com/forums//showthread.php?t=182071
"This is the front side. The splined shaft is the input, and the round connector hooks up to the driveline to the front wheels. They turn together only if the clutch is engaged inside the transfer case."
I read enough to assume that this shouldn't be happening. Is something wrong with the transfer case? maybe the clutch? maybe a wire somewhere is loose? I'd really appreciate any help that the pros in here could offer.
also, nothing else seems to be wrong, no flashing 4wd lights, no problems engaging 4wd auto or 4wd low. Also, the CAD seems to be working fine since the front tires do not get any power from the front shaft as it spins. Again, your help will be greatly appreciated.
the TC model is "F57A-7A195-CA", which makes this transfer case a part-time electric shift model (I think). and the selector on the dashboard has 2wd, 4wd auto and 4wd low.