what could it be?

[me7]

i started a thread before because i was hearing loud thud noise when i would take off in my X and the noise was especially bad when i had my X on 4wd on slippery terrain (mud/snow). the noise was especailly loud when i start from a standstill, give it alot of gas, or if im going up a steep hill.

this past weekend as i was offroading the noise got especially bad, as i said the noise is a deep thud that shakes the whole car that seems to be comming from the middle and toward that front of the car. the noise gets faster the more gas i give the car. as i am putting the car from forward to reverse i can hear something grinding. after a while driving like this in the trail my 4wd and O/D lights started blinking. fearing that i could get stranded i headed out to paved road asap. after a while driving on paved roads and having the car on auto 4wd setting the lights went away. but the noise would still come up when i would floor my X.

ive taken my car to ford a bunch of time and each time they said that my transfer case needed rebuilding. each time the problem seemed to go away but nothing was permanent it would always come back. ide hate to keep on taking my car back to them cause it cost lots of $$$ each time. my buddy suggested to me that there had to be something else wrong with the car which could be causing the trasfer case to go bad? any ideas? or should i just pull my transfer case all together, ive got nearly 125k miles on the car.

 

[Bigred08046]

Sounds like torque converter. Better get it before it breaks flexplate/flywheel. Flashing O/D lite and vibration is the hot tip.

 

[Mbrooks420]

Sounds to me like you've junked the Torque on Demand clutch in the t case. These aren't very stout and don't take abuse to well. Does it make and popping sounds, and seem to slip, then catch?