transfer case shifting out of gear on hwy.

[d4dug]

97 explorer shifts out of gear into a neutral when throttle is released (coasting, engine braking) shifts back into gear when throttle is pressed. Loud noise when it goes into neutral and freewheels. Any ideas? thanks dug.

 

[coled43]

Welcome to the site, Dug. I experienced the same problem on my 97 a couple of years ago. It seems to be a somewhat common problem and you will find a good deal of posts about it if you search this site, but it took me a while to find out the whole story on it. The bottom line is that you will have to replace or rebuild your transfercase. There are issues with the case having wear on the shift rails that causes repeat failures if a standard rebuild is done. I would suggest Rockland Standard Gear (1-877-RSG-GEAR http://www.transmissionsandtransfercases.com/ )for a quality rebuilt unit, probably about $1200. I ended up getting one from a junkyard for around $600. It is still fine after 30k miles, but who knows. I think it is a planetary? gear that slips out of engagement. For me it happened very intermittently at first, but got bad enough that I couldn't even drive down the street. One thing I did figure out was that turning off the OD and keeping the gas under slight pressure while stopping kept it from slipping out. Thats how I drove it to the garage where I got the T-case swapped. If it is only happening to you on the highway at this point, turning off OD will probably stop it. All of the information you need to do the job yourself or get it done right is on this board. Good luck.

 

[d4dug]

thanks, I live out in the bush with veerry slow dial up It took a while but I think I found what I need. Excellent Board Thanks again.

 

[rjhusak]

Hi..
Welcome to the list as well..
I had exactly the same issues.. Untill it sarted make some really horrible noises.. I had the transfer case gone through but the "neutralizing" soon came back.. I ended up having to replace the case. These folks (The Rebuilder) specializes on these and has a "fix" they said that the case gets "hogged out" where the cam shift shaft goes int the case they line bore it and bush it. They also have a redesigned cam with different angles.. Or something like that..
Any how.. The shop who did the origional repair said.." It can't be the case" "If it is I will refund your money and install this one for FREE".. Oh Well.. I actually would not take all of the money back but it's been 7K and all is well..
Good luck.. I think I paid about $800 exchange plus frieght..
Ron