Transmission/Transfer case problems!! :( 97 Ford Explorer XLT 4.0 V6 | Ford Explorer Forums

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Transmission/Transfer case problems!! :( 97 Ford Explorer XLT 4.0 V6

Dan725

New Member
Joined
April 13, 2006
Messages
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City, State
La Jolla, CA
Year, Model & Trim Level
'97 XLT 4.0 V6
Hi, I'm new here, and I was refered here by a member of another forum. He refered me to a really helpful member here named Glacier991.

Before I begin, from the few pm exchanges I had with Glacier991, he's geniunely a nice person, and a very knowledgeble person. In posting this, I am in no way saying that he is not capable of helping me, lol.

I'm posting this here now because I want multiple inputs on this situation, and I do not want to put all the burden on Glacier991, who has already taken his time to help me w/ his pm's.







K my story:

At first I thought it was the transmission making the noise.
It makes a loud, geary noise everytime I let my foot off the accelerator, and it only happens when I go above 40 mph or so. It seems, after the tranmissions goes past 2nd or 3rd gear, and I let my foot off the petal, the loud, geary noise comes on.

I just have to press on the gas to make the noise go away.

The sound is originating from the transfer case. (the mechanic helping me told me this)



The car actually runs perfectly fine w/ no noises when the 4WD is set to "LOW."

Once it's set to "HIGH," the noises come back, AND, reverse no longer works.

Also, after reving the engine over 3k for long periods of time, the overdrive light starts blinking, and the next part I'm not sure if I can explain properly.

The OD light keep blinking, and it seems that OD is off (half way). Usually when I turn off OD, the engine will rev a lot higher. This is expected. And When I turn off OD, it revs lower.

But now that it's blinking, it revs higher, when the OD is percieved to be off, the RPM higher than normal, but not as high when OD is actually off.

or in other words...
While the light is blinking, and I turn off OD (at this point, I can't tell if it's on or off by just looking @ the light... I can only tell if OD is off when the engine is reving higher), the engine revs higher. When I turn if on, it revs lower, but not as low as when the OD light is not blinking.


This goes away after I leave the car overnight.


The mechanic disconnected the transfer case's ability to go into "LOW" and "AUTO" mode, and did something so the geary noises does not come back while under "HIGH" mode.


So, now, is it OK to drive in this type of condition? I doubt it, but oh well. I really need the car for obvious reasons (work..heh).

I essentially lost the transfer case's ability to be in "auto" mode, and it can never go into "low" mode. With this, the car runs just like it did before, except, that on some occasions, when I accelerate, it feels like the car's running on 3rd gear instead of 1st gear (so it accelerates slower than usual).


I fear that when I go to the dealer, they're goign to strip down everything, replace everything, and charge me an incredible amount of money.


sigh :(



oh and one other thing, lol. does anyone have the 97-era ford explorer xlt car manual in a PDF file? During the years of having this car, I seem to have misplaced it :(. :navajo:
 



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I just fixed one with the noise you describe and no reverse. I found a streched chain and broken shift-fork in the transfer-case. You initially would have thought it to be a tranny problem.
 






Dan725 said:
The mechanic disconnected the transfer case's ability to go into "LOW" and "AUTO" mode, and did something so the geary noises does not come back while under "HIGH" mode.So, now, is it OK to drive in this type of condition? I doubt it, but oh well.
You're right, its not okay to drive the vehicle on pavement permanently on 4HI.

Hmm "disconnected the transfer case's ability to go into LOW and AUTO" <- thats interesting because, as you may know, the transfer case's 4WD ability is engaged via an electromagnetic driving a clutch pack. Did your mechanic remove the transfer case from the vehicle and opened it?

je5 said:
I just fixed one with the noise you describe and no reverse. I found a streched chain and broken shift-fork in the transfer-case.
Hmm this is interesting too!! What did it sound like when you put the vehicle in Reverse and pressed on the gas?
 






You're not the first person to have this problem with the transfer case. As IZ mentioned, the diagnosis is suspect. The most common cause of that noise is transfer case issues. I've heard estimates for repairs from here ranging from a few hundred to $1800. Omega makes some good upgraded replacement components for the case should you choose to go the rebuild route.

Also, I'm with IZ... no way your mechanic locked it in 4 high. It's all electronically controlled by the GEM and the Transfer Case Shift Module.

-Joe
 






IZwack said:
You're right, its not okay to drive the vehicle on pavement permanently on 4HI.

Hmm "disconnected the transfer case's ability to go into LOW and AUTO" <- thats interesting because, as you may know, the transfer case's 4WD ability is engaged via an electromagnetic driving a clutch pack. Did your mechanic remove the transfer case from the vehicle and opened it?

Hmm this is interesting too!! What did it sound like when you put the vehicle in Reverse and pressed on the gas?

Ratcheting metallic sound. Vehicle would not move in reverse and parking pawl would not hold the car. Would drive forward with this noise when coasting. I will rebuild cases for very reasonable labor charges.
 






now the problem is, that I cannot find anyone that deals with transfer case rebiulds :(

If anyone knows one in the So. Cal. area (preferably around east LA towards pomona areas), let me know :).


The mechanic told me that he just took out the electrical cord that power the components to do what he did.


Thanks much for the replies though.
 






Not sure how far LA is from Sacramento, but try www.omegamachine.com. Not only can they rebuild it, they'll make it better than new! :)

-Joe
 






Dan725 said:
now the problem is, that I cannot find anyone that deals with transfer case rebiulds :(

If anyone knows one in the So. Cal. area (preferably around east LA towards pomona areas), let me know :).


The mechanic told me that he just took out the electrical cord that power the components to do what he did.


Thanks much for the replies though.
www.jasperengines.com
 






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