transfer case clunk ?

[UxHamby]

Hi,

We have a '98 5L V8 Explorer that we quite like. It came to us history unknown at about 150,000 kM's, the body is in good shape and it looks presentable. Currently it has about 204,000 kM's on it. It has the full time on demand 4wd, although it has always been on pavement since we have owned it. As I say, we quite like it.

It suffered some unintentional abuse just after we got it. Seems the seller put the wrong spare wheel & tire under it, presumably to make the spare wheel well look occupied. My son borrowed the car and got a flat so he put on the spare and drove on. Well smoke and screams brought him to a stop a few miles later as the front axle was toasted by the one wrong size tire. Only after wards did we get wise to what had happened.

OK so I pay to have a replacement front axle from a wreckers installed by a ford dealer some distance from home where the mishap occurred, and all is good again. This would be at say 165 or 170,000 kM's or maybe a bit more. The car ran well and seemed back to normal for some time.

Approaching 200,000 kM's the car starts to clunk in slow maneuvers like tight turns. It gets worse gradually and now any time you accelerate away from a stand still too hard it clunks. Actually lately, it is getting difficult to accelerate away from a stand still gently enough to avoid making it clunk. Sounds like a spline slipping or a chain jumping a tooth on a cog.

There is also a sort of crunching sound if you drive the car slowly at say a walking speed. This happens in forward and reverse. The crunching noise has been with the car as long as we have owned it so far as I can recall.

Once at speed the car moves handles and accelerates as normal and is quite nice to drive.

Our local ford dealer says they have isolated both of the noises to the transfer case. They quote me $2300.00 to rebuild. Another one man band general repair facility that I use & trust, has quoted me $1900 - $2000 for the job where he does the re & re and farms out the rebuild to parties unknown.

I am inclined to get it fixed as I don't see replacing this vehicle any time soon. I'd like to get some opinions from experts here about how difficult a job transfer case removal is ? What is the likely hood that the history of abuse is the cause of the current clunk problem?

I don't mind getting my hands dirty and can swing a wrench with the best of them. I have done upper engine work on cars and bikes. I have a reasonably well equipped home garage, yet find the prospect of drive line work on this scale daunting. Is it possible for a weekend home mechanic to re and re a transfer case? Are there any tech articles on this problem / procedure that I should read?

I am thinking of a scenario where I remove the transfer case and have it rebuilt by some expert shop somewhere and re install it again here.

Am I on drugs ? Any recommended shops in the Toronto area? Other options?

Thanks,

Brian H.

 

[gavin]

it's a full-time all-wheel drive transfer case, not "full time on demand 4wd"

it's a fully mechanical all wheel drive system, where power output is split 30/70 front/rear (or something like that), by a viscous coupling.

in case you feel like reading up on this t-tcase
http://www.explorerforum.com/forums/showthread.php?t=225515
http://www.explorerforum.com/forums/showthread.php?t=218430

but to answer your question; it sounds like it could be the viscous coupling. From everything I've read, you will get this popping/clicking sound at slow speeds and sharp turns, when the VC is going bad.

I'm currently having the same issues with mine, and I even have the front d-shaft disconnected (I thought I was getting a lot of driveline binding due to a frozen VC). Although I haven't determined if the noise is coming from the t-case since I only hear it when I'm pulling into the parking garage at work. I'm currently waiting on my new BorgWarner viscous coupling to come in so that I can rebuild the t-case yet again.

chances are, and they are very very very good, is that the odd-ball spare essentially fried the VC.

 

[UxHamby]

thanks gavin!

Thanks for the excellent info gavin!

Looks like more than I am equipped to tackle from a time commitment standpoint. In my ideal world, I'd do this job myself but in reality land I think I need to get it done out ASAP.

Anyone got any suggestions on good shops for this work in the north east Toronto area?

Thanks,

Brian H.

 

[rizzjc]

It could easily be done in a day (or half a day) if you're prepared ahead of time. You can buy a used transfer case for around $200, unbolt the old one, and bolt in the new one. It's really (just about) that easy.

Or, if you don't want to spend $2k on a new one, see if you can find used, and find out how much your local shop would charge to put it in.

 

[gavin]

honestly I would be weary of purchasing a used 4404 t-case. Why? No clue how the owner took care of the vehicle the case was in; it could possibly have a fried VC in it, and you wouldn't know 'til you get it installed. Unless you get the case for dirt-cheap (here in Alaska, every 4404 I've found at a junkyard cost ~$500+). But, that's just me.


Seriously? It's a quick project, really. Granted, I've already had my case apart twice, but it's still not to many parts to get lost.

The viscous coupling itself will run you right around ~$300 US.

 

[rizzjc]

Well, I think most junk yards will warranty the part for a short period. It's a hassle, but since I was looking to spend $200 instead of $1500 (or was it $2500??), it was worth it. I do still have the old TC that I might rebuild one day. I now have almost 50k miles on the replacement I put in it. I'm all for brand new most of the time, but that I was a huge chunk of change that I didn't want to spend at the time. I had just had the real seal replaced and that cost me $800.

Although probably not the most reliable data, places like car-part.com list the miles on the unit, if known.

 

[UxHamby]

Tools & prep?

It could easily be done in a day (or half a day) if you're prepared ahead of time.

What exotic tools does one require? What special preps ?

Might I find a rebuilt one somewhere that I could get a deposit back when I return my defective one?

Thanks guys!

Brian H.

 

[gmanpaint]

I purchased a used one and it has a full year warranty. I installed it myself in my driveway in a couple hours. I just read some threads on how to do it, and it was really pretty simple mentally. Physically, it can be a bear to lift up (bench press) and slide on the trans output shaft. I actually pulled it 3 times in a week. It got faster each time. Don't need many tools, 8mm, 10mm, 12mm, 13mm, wrenches. A 10mm socket, and some jack stands.

 

[gavin]

What exotic tools does one require? What special preps ?

Might I find a rebuilt one somewhere that I could get a deposit back when I return my defective one?

Thanks guys!

Brian H.

for rebuilding one?
Check out my thread
http://www.explorerforum.com/forums/showthread.php?t=218430

only necessary tool would be a slide hammer with bearing puller adapters.
a blind-hole puller is necessary for atleast one of the bearings, another one was tough with a standard bearing puller.

 

[rizzjc]

Slide hammer? Bearings? What for?

I think he was asking about replacing it - not rebuilding it. Nothing exotic needed. I did invest in a set of metric ratchet wrenches to remove the bolts from the transfer case to the extension housing. Only thing I could find that would fit a few of the lower ones. Also need to remove the center console and cut the carpet under it, to get to the access panel in the floor. First time I did it, I removed the seats to get the carpet out in one piece. I learned from that and cut it. No ill affects. Other than that you'll need a socket set with some extensions and swivels.

I drove it up on 4 ramps for more access, and used a floor jack to hold the transfer case. An extra body helps so you can be under the truck with the transfer case, and another person on the jack.

 

[gavin]

Slide hammer? Bearings? What for?

I think he was asking about replacing it - not rebuilding it. Nothing exotic needed. I did invest in a set of metric ratchet wrenches to remove the bolts from the transfer case to the extension housing. Only thing I could find that would fit a few of the lower ones. Also need to remove the center console and cut the carpet under it, to get to the access panel in the floor. First time I did it, I removed the seats to get the carpet out in one piece. I learned from that and cut it. No ill affects. Other than that you'll need a socket set with some extensions and swivels.

I drove it up on 4 ramps for more access, and used a floor jack to hold the transfer case. An extra body helps so you can be under the truck with the transfer case, and another person on the jack.

see... this is why my first line says:

for rebuilding one?

 

[fordnut71]

you can find a used 1 at
http://car-part.com/
i use it all the time to search an compair prices.

 

[UxHamby]

update

Hi, FWIW this is how this turned out.

At long last, I had this job done by Kevin Mugford's Durham Transmissions, a one man band transmission shop in north Oshawa Ontario:

The price was right, much cheaper than any other quotes.

So far so good.

I liked him, he was very honest and forthcoming with info and suggestions, even calling me in to see the dismantled parts. Apparently the fix was a used VC clutch and a new chain in the transfer case.

I like a one man band shop and avoid those clean hands & white coated dealership service advisors like the plague.

Thanks Kevin!

Brian H.

 

[UxHamby]

Still going strong

Just thought I'd update this.

The truck is still going strong now at 240,000 kms or so.

Brian H.