What is the correct way to clock the transfer case so it will line up with the new transfer case shift motor. I have read that you should not clock the transfer case shift motor.
View 8 RepliesDo we need to drain the fluid to change the transfer case motor?
View 3 RepliesI have a 03 Excursion 6.0 that just developed a transmission leak between the transmission and transfer case. It appears to be the transmission because the transfer case fluid is at the top. I started to notice transmission fluid leaking in my driveway. I have not had any driving issues with the transmission but I am not driving until I correct the problem. If this is the rear transmission seal, how had is it to change this seal? Must I remove the spacer between the transfer case and 5r110 tranny? Any special tools needed?
My temps have stayed at or below 150 if I recall. My fluid is slightly low in the transmission at about 134 operating temperature. The fluid is clean, red and has no burnt odor. My transfer case is topped off. Fluid ran out the fill plug when I removed it.
There is an aluminum square spacer than necks down. It is about 6" long between the transmission output on the excursion and the transfer case. The leak I see is where that spacer meets the transfer case. I see enough for the fluid to leak onto the cross member and to the driveway. I estimate that I have lost less than a 1/2 quart of fluid over a couple weeks.
My TC motor picked today of course with the snow to go bad. Luckily I hobbled to advance right as they were about to close and got one. I laid in the snow and changed it. Needless to say I got soaked beyond belief. Anyways now it changes in and out well but still seems way to loose in the rear. Not sure if something else is malfunctioning or if these things are like that. Right now I don't feel nearly as safe as I did in my expedition and that was without even using 4hi or low just the A4WD. The excursion is sliding everywhere. My tires have great tread but are highway tires so maybe that's the issue. They are Dura Grapplers. I'm going to try throwing some weight in the rear to maybe gain some traction.
View 2 RepliesI have this 99f250 and it has a 273f, the transmission side of the case has threads stripped so I am about to remove and retap them. While its out should I consider rebuilding this thing? 197k miles, operates decently although the rear bearing on output side is my first thought to replace from mileage only.
View 1 RepliesI bought a 2000 Ex PSD 4x4 in september. I have refreshed the suspension in the last 4 months; leafs, shocks, etc. I developed a vibration over 50mph after I installed the suspension and have been chasing it since.
I have replaced the U Joints, professionally balanced and lubed driveshaft twice, adjusted driveshaft angle to less than 1*, replaced the flanges for the TC output and the driveshaft companion flange. I have not touched the diff, but there is no decernable play in the pinion or leaks. Also, I removed the rear housing of the TC and replaced the output needle bearing and seal 2 weeks ago.
The output of the TC still has 1/4" play and a clicking noise coming just forward of the chain section of the TC. I assume the play is coming from other bearings on the main shaft in the TC.
I am about to purchase a remanufactured TC, but before I do, I need a reality check. Is it possible there is damage to the output bearing of the Transmission or something else?
I don't want to buy a TC to put in and experience a TC failure again in a short time. It doesn't make sense to me that there would still be so much play after changing the output shaft needle bearing of the TC if the TC main shaft is supported not just from the TC bearings but the output of the transmission unless there was possible play in the output of the transmission.
Truck is an 03 F350 with the 6.0. It sometimes sounds like the shift motor on the transfer case is trying to engage. It has the vacuum system which is blocked off. Warn aftermarket hubs. Switch on the dash with 2wd, 4wd and 4 low.
It's kind of an off and on thing. Try to engage for a few or more seconds then nothing for awhile then repeat. It sounds like it's at the transfer case. It could very well be coming from firewall/engine bay area as well. Is there anything between the dash switch and the motor?
I'm in the process of changing my shift motor on my 04 f350. I can't get it off because of a broken bolt. The previous owner must have done this before, and snapped the head and some of the shaft off, so it's basically an alignment pin that's recessed into the hole on the motor. For some reason it's holding the motor on, even though I don't think the hole is threaded. Any way to get it off. I'm thinking that taking a MAP gas torch to the casting on the motor may be my best bet.
View 8 Replies2001 F250, 7.3L ... After much diagnosis, I've found that the 4 positive feeds to the transfer case relay base have no power to them. The fuse that feeds them (#17 CJB) is fine and when I jump from the fuse hot side directly to the transfer case motor contacts on the relay base, it shifts fine. As far as I can tell, there is only one wire leading from that fuse so there must be a junction block somewhere that splits it into the 4 wires that feed the relay block. I've looked underneath and found nothing. How the 1 wire gets split into 4? On diagrams this junction point is labeled, but I don't know where to find that.
View 2 RepliesAfter driving, i smelled something horrible burning. When I get home, I get on my creeper and roll under to look for anything suspicious, and I find this. It is not where the drain plug in the pan is, it's in front of that. I checked the temp when I was driving but it never got high. I really need my transmission to not explode on me right now, I have a lot of driving to do.
Here's a gallery where there are some pictures....
Photo Album - Imgur....
Couple weeks ago found some oil drops in the drive way so I got Underneath to see this disappointment. Hope the pictures come through for you all to see. She's been in the shop since Monday.
front crank case seal gone bad! what a mess.
I started having an oil leak under my truck in the last week or so and when I went under the rig briefly (it is raining here) it looks like it may be either coming from the oil pan itself or the seam between the tranny and engine case.
I thought I'd try the easy solution by torquing the appropriate bolts. Looking for the torque specs for these two sets of bolts or have any other suggestion where the oil could be coming from?
I have ~130K on the truck.
Looking at another Ex but the owner says the transfer case does not engage. Says it can be locked into 4X4 by crawling under it and engaging it manually by removing a motor [Servo motor ?] Does this mean I would need a new transfer case or just the servo motor ? I know mine did the same thing last winter. It would go into 4X4 and then pop out.
View 10 RepliesI just replaced the transfer case BW 4405. And I noticed that the 2 sensors (front drive shaft and rear drive shaft) are bad. What is the name of these two sensors? I'm looking for a brand new ones...
View 13 RepliesWhere/how to check the ATF in the transfer case? I found the lower drain bolt,but I don't see anything up higher that looks like a fill hole.
'91 Aerostar 4.0L AWD
2003 ex 6.0 limited....300000 miles ...Automatic.Merry Christmas to all.My Transfer case will not shift into 4wd . Dash light for 4wd high and low works .I get no power to transfer case 2pin connector when key turned on.Also fuses 19,27,31,33,34,45,111 are all good when checked with meter.I also swapped 2 relays in engine compartment and no change.4 WD Switch on dash has power on Green/red wire I think it is for dash light and not for operation.
View 13 RepliesSwapped out my transfer case since mine was detonated and now my tranny is running hotter? Drove in town for about 10-15 minutes and noticed my temps climbing and once it got to 180 it felt like it was slipping when moving from a full stop. i went home and parked it. Checked my fluid level and it looked a little low so topped it off while running and went through gears to make sure it was good. Drove again and it still went up to 180 in 10-15 minutes in town driving. Before we swapped the transfer case it was driving fine and went on a road trip 6 hour drive and felt fine. I bought the excursion and it supposedly had a new tranny in it.
View 14 RepliesSo long story short I have a 92 Aerostar AWD which I'm pretty sure had the transfer case recall done (97V204000 1992 FORD AEROSTAR Recalls) it has the aluminum driveshaft but a couple of years ago the transfer case cracked and I replaced it with a "New OEM" transfer case off eBay. Fast forward to the present and my van has a strong vibration at 60+ my transmission guy says it all looks good so the vibration has to be from one of the driveshafts. My thought is that I may have got a transfer case without the recall done on it and its warped my driveshaft. I don't really know thats possible or what I could do about it if that was the case.
View 8 RepliesI bought a new to me 03 explorer 4.6 tow package XLT 136000mi. Rebuilt aamco trans with 10k on it. Been checking it over before i put it on the road.. No 4x4 but the button lites work and i got into low range once. (Had a hell of a time getting back to high but eventually it did). Question is if there is 12v at the brown wire on the TC the case should be fully locked? I figure when i check it if there is not 12v at the brown wire in 4x4 high i could apply 12v directly with a jumper wire to see if the case locks to 4x4. Am I correct?
View 2 RepliesAbout 9 months ago heard a strange noise when shifted into 4 wd , sounded like driving over those grooves on the side of the highway to keep people awake.
Had to pull over to stop , as it would not go back into 2wd with the noise still going.
Then it stopped , after shutting truck off and restarting.
Then earlier this year after trying to do it again in 4wd had bad clunking noise and was hard to get back in 2wd , I can here the shift motor engaging and the dash reads in 4wd, seems its not engaging fully in 4wd and not going back to 2wd, its a very bad clunking noise, shakes the whole truck.
The dang thing leaks from the fill plug, I been reading about using liquid teflon on it.
View 4 Replies