Transfer case problems

[burgo]

I'm getting a grinding clunk sound when I engage the 4x4 low on my '97, Ford tells me "this is normal" and I call b.s. Am I wrong? I also still get some power to the front wheels when I unplug the transfer case solenoid, or splice in a switch to the brown wire under my drivers seat. I hear, according to the several threads on disabeling the control trac, that this should not be happening. What the HELL!!

 

[Billy177]

the brown wire mod does not apply to 97's and the clunk is normal

 

[Ak LTD Xplorer]

the brown wire mod work's on 97-01 ex's the new ones also..this would give you true 2wd if you did the brown wire mod..

the clunk is normal

 

[burgo]

Thanks for the input on the transfer case clunk, but I still don't understand why putting in a switch, or unplugging my solenoid, does not result in two wheel drive. I don't get as much power to the front, but there still is some. I hope that something isn't f#*ked!!

 

[Yomie]

Originally posted by burgo
Thanks for the input on the transfer case clunk, but I still don't understand why putting in a switch, or unplugging my solenoid, does not result in two wheel drive. I don't get as much power to the front, but there still is some. I hope that something isn't f#*ked!!

How did you test to see if you were getting power to the front?

I have this mod done on my '97 and it works flawlessly

 

[burgo]

I was on some gravel and put my fot to the floor. The front end just kinda bounced and hoped, while the back tires spun like they should. That is no good at all and I soon plugged everything back in like it is suppose to be.

 

[beeree1]

I also have a 97 4.0SOHC VIN E, 5 Speed Auto, with a Borg Warner 4405 transfer case. I've been having problems with the front hubs locking into 4wd by themselves, it seems the only way to get them out is to put the tranny in nuetral and switch from "AUTO" to "4LOW" and back to "AUTO", it then disengages the 4wd. I had read that some had spliced a wire in to the switch on other ex's and gotten 2wd so I tried disconnecting the switch to see what would happen. It still went into 4wd the next day and had to do the same again to get it out. I checked the fluid level in transfer case and was good. Any help would be greatly appreciated. Thanks.

 

[Opera House]

Are you talking about the switch on the dash you disconnected? This is just a resistance switch 3.9K=auto, 1.1K=4HI, 360=4LO. The shift motor only has 3 functions, HI, Neutral, and LO. 4WD is selected by operating the electrical clutch. Only the brown wire will disconnect the clutch. Even then, the clutch still has a lot of drag.