Whining sound (downhill) & 4WD issues. Transfer case?

[watson316]

Hey guys! First time poster, long time lurker. Love the forums. In the past I've been able to get the information I've needed by using the search function. There are posts with a similar issue with what I'm having but between the different variables and suggestions I am clueless as to what my issue is. I figured by posting my specific problem I'd at least know what direction to go.

I have a 1997 Explorer 4WD. Ever since I first got it when I put it in 4x4-High or Low (my 4x4 options are Auto, High, and Low) I would get this grinding sensation when I turned. The sharper the turn, the louder the grind. It didn't happen on Auto 4x4. Now, about a month ago it started doing the grinding while on Auto. My wife took it to a local mechanic. He drove it around and said he seemed like it was getting stuck in 4WD. He said it was a problem inside the transfer case or the case itself. We didn't have the extra money at the time to have him dive into it to see what the problem was. He said it would be okay to drive it but the problem would just get worse.

So when I got home I did some research on here about how to stop the 4WD from engaging. I saw that there is a Brown Wire Mod but, as pathetic as it sounds, I don't have the tools nor the aptitude to do it. What I did was remove the fuse (under the hood) that powers the 4WD system. Ever since it has ran great, no problems. Until today.....

On my way to work this morning, it was running fine until I began coasting downhill at around 50 mph, suddenly I heard this load winding/whining sound. When I stopped and started driving again on the flat road, it stopped. It done it some more on my way home. It always does it while going downhill and hitting the gas or brake doesn't make it stop, only putting it in Neutral does. Based on what I have read on here and the 4WD issue, the problem is most likely the transfer case.

So what I'm wondering is, does that sound like the culprit? Did me pulling the 4WD fuse disable the 4x4 system? and finally, with a transfer case problem being such an expensive fix, I can fix it right away. So, realistically, how much time do I have before I'm stranded on the side of the road? I'm not having any other symptoms other than the noise. Gears change fine, acceleration is smooth. The only thing is my transmission fluid is brown but I wouldn't say "burnt". Other than that it seems fine. But what do I know? LoL. Thanks for your time and knowledge, guys. I really appreciate it. Have a good day!

 

[drdoom]

Won't be long, the transfer case is going to need a rebuild. When it goes, you may be able to put it in 4LOW to get off the road. What's happening is the mechanism in the case that holds the high range in place is worn, and could be as little as shift fork pads or likely you will need a fork, range slider, maybe some sleeves machined into the case halves. If you want to read and see more, find the 4405 rebuild diary in the transmission sub-forum.