transfer case slips out of gear

[97sport]

Big problem... While towing my boat back home, OD off
it came out of gear makeing a high pitched ZZZZZ. It sounds like it is comming form the transfer case. It happend twice before i could get off the HWY.Q is there a electric motor responsible for locking the truck in gear?
Has anyone had this problem... HELP!

 

[Robert]

My '97 did the same thing on a few occasions a little over a year ago. It did it after I had removed my transfercase shift solenoid to clean the speed sensor behind it. When I put the solenoid back in everything seemed fine. The next time I had it in 4x4 Low and then switched it back into Auto after wheeling it made the grinding noise and felt like I was in neutral. It did this about 5 miles or so after putting it in Auto. I pulled over and stepped on the gas. When I did my engine went "ZZZZZZZZZ". I tried putting it in park, no noise so I figured it was a fluke. I put it in reverse and had no reverse and the noise was back. I shut it off and restarted it. The noise was gone and didn't come back for the rest of the trip. The next time I used Low, it wouldn't come out of Low until I shut off and restarted my Explorer. After a few episodes of that, the problems haven't been back. I have used High and Low on many occasions during the last year without anymore problems. I figured that I probably got the worm gear mis-aligned and it took using it a few times to get it "homed" properly. I suspect that what you are experiencing is related to your shift solenoid.

 

[97sport]

transfer case clutch ***

Well i took my truck to the dealer today because i'm lost when it comes to transmisions. the bad news is that the clutch is sliping away form the gears and causing the grinding, ford does not reccomend rebuilding. to have it replaced will run $2300. the dealer is looking into some asistance from ford. but with 67k they doubt it. the part cost $1800 so i think i could save some money if i could put it in myself. how hard is it to put in? do i need special tools or experience. the part won't be in until 8/9
so any insight would be greatly apreciated.

 

[bplein]

What was the final-final on your transfer case problem? Did it end up being what Ford said?