Viscous coupling?

[BCOLE6]

I have a 2002 Explorer. From researching this site it sounds like my viscous coupling is locked up, but not sure if I have one. All the posts I read on viscous couplings mention AWD vehicles. Is mine considered AWD? I have 3 push button selections , "4wd auto" , "4wd hi" and "4wd lo". Symptoms are binding, popping at slow speed while turning, especially in reverse while in the "4wd auto" selection. Any info would be appreciated greatly. Thank you.

 

[grkstl2]

You dont have a viscous coupling. I have the same issue with my 02 and it has 3 buttons as well. After a bunch of research I think that our transfer cases just need to be rebuilt...

 

[imp]

I have a 2002 Explorer. From researching this site it sounds like my viscous coupling is locked up, but not sure if I have one. All the posts I read on viscous couplings mention AWD vehicles. Is mine considered AWD? I have 3 push button selections , "4wd auto" , "4wd hi" and "4wd lo". Symptoms are binding, popping at slow speed while turning, especially in reverse while in the "4wd auto" selection. Any info would be appreciated greatly. Thank you.

You do NOT have a viscous coupling; they are used ONLY in the AWD transfer case. What you DO have is an "electronic clutch" which engages to provide power to the front wheels when the computer tells it to do so. For all normal driving conditions, where traction available to the tires is basically equal on all four tires, the clutch simply allows free rotation with NO POWER supplied to the front wheels at all.

Your symptoms suggest the clutch is bound up, and therefore driving the front wheels, with the result that with good traction available to all four tires, like on dry pavement, the difference in rotational speed from front to rear tires is causing them to slip, hop around, bind, and make noise. This condition places EXTREME stress on all the driveline parts, and occasionally BREAKS things like U-Joints.

The recommendation that your transfer case needs rebuilding is correct. imp

 

[BCOLE6]

Thank you for your responses. I should be able to remove the front driveshaft to eliminate stress, correct?

 

[imp]

Thank you for your responses. I should be able to remove the front driveshaft to eliminate stress, correct?

Yes, you can. However, please be aware at the same time, the process which caused clutch problems in the first place may have caused the making of debris, metal particles and chips, which now are circulating within the transfer case and will eventually damage parts severely, bearings included.

Some recourse may be had when (if) you remove the front driveshaft, by draining the contaminated oil and replacing it with fresh fluid. imp

 

[BCOLE6]

Thank you. Took front shaft out this morning, all noises are gone. But in order to restore 4WD, I need to have t-case rebuilt ? And does anyone know what transfer case I have in this vehicle?

 

[jrford]

should be a Borg Warner 4411 (you will have 3 switches on the dash). . .most common failures, module behind the dash or the shift motor.

You might not need to rebuild it. . .You should be able to mount the drive shaft and just unplug a fuse. . .not sure which one. However if the binding is back which drive shaft on, and fuse pulled, you xfr case might messed up. That would be rebuild time.

this might be similar?
http://www.explorerforum.com/forums/showthread.php?t=296942

 

[imp]

should be a Borg Warner 4411 (you will have 3 switches on the dash). . .most common failures, module behind the dash or the shift motor. .......

Please, which module would this be that you speak of? Asking cause I have a 44-11 giving me fits. My shop manual (Ford) says the 4X4 Module is incorporated in the PCM and is not serviceable separately. Yet, that same manual shows two electrical connectors which are "4X4 Module" connectors, and includes resistance check numbers...BUT, neither connector is shown, or even mentioned, nor is the 4X4 Module shown or mentioned, in the official Ford Motor wiring diagrams!

So, what is one to do?? imp

 

[jrford]

sorry i forgot they changed it in '04, but yep it looks like they moved it. . .some threads
http://www.explorerforum.com/forums/showthread.php?t=236130
http://www.explorerforum.com/forums/showthread.php?t=250848
http://www.explorerforum.com/forums/showthread.php?t=178819

 

[imp]

Thank you for the links, jr! imp