Ford Transmission :: Transfer Case Noises When Shifted Into 4WD
Oct 5, 2015
About 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.
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I own a 2006 mazdaspeed 6 with 90k+ miles, 2 weeks ago I had a 90k service done at the dealership. On the 14th of May, the 90k service was done (which includes the changing the transfer case fluid/oil). Car was not driven every day, but on the 23rd of May the car made horrible noises on the way home from work. I called a flat bed/tow truck, and have tried to lock in the problem. The sound seems to be coming from the transfer case.The question is could they have done something wrong or was it just the transfer case’s time to go up?
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I have a BW 1345 transfer case. Does it have the shift in the fly capability? And, if so, what precautions should be taken if shifting on the fly?
Second, where can I get a "plate" or label that shows the shift pattern? I know the shift pattern, I just want to post it in my vehicle in case anyone else ever drives it and needs to use the 4 wheel drive.
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I found that my transmission was low on oil but couldn't find a leak. What I did find is that the seal in the transfer case was letting trans fluid transfer into it and then it would leak out the out put seal. I purchased the new seal and gasket and repaired it myself in about 3 hours. I removed the rear drive shaft and removed the front drive shaft from the transfer case alone or you can take it out completely if you want.
Drained transfer case unplugged wiring and one vacuum line. Unbloted from trans and removed using trans jack. The bolts are not the easiest to get to. i used a 3/8 ratchet to break them loose then used a stubby 3/8 to get them out because they are around 2 inches long. Once down I had to jack up the truck to get it out from under it. I removed the old seal and installed new one cleaned everything up and installed with a new gasket.
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I have a '95 F-250 7.3 auto 4X4. The transfer case linkage has been floppy and prone to coming apart since I've had it, but that's been fine for me. I let my brother use the truck last weekend, and now it does the following: When you put the transmission in reverse, or when the truck overruns the engine (compression braking) it grinds badly like the transfer case isn't quite engaged. Only does it in 2 or 4 Hi, and everything's normal otherwise.
Could the transfer case have jumped out of gear while he was driving it, and he didn't know to either push it into gear or pull it into neutral before it did damage? I really don't want to pull a transfer case in my driveway in December in New England, but give it to me straight.
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My 2000 explorer has picked up a clutch chatter when taking off with the wheels turned. It is AWD, and has an 8.8" LS rear end with and 173k on the clock. Is there any good way to tell where the chatter is coming from? I know how to check the TC clutch, but it requires dropping one of the driveshafts.
I may try changing the rear diff lube, as I am sure it's never been done. They say "lube for life" but no fluid can last forever, I would think.
Also, on that note... a couple years ago I had a pinion seal leaking and the shop said it was 2 quarts low when they fixed it and said "rear diff damage has probably already occurred" on the ticket. While that is possible i suppose, would think i would have major problems right away as the diff only holds 2.5 qts (IIRC). Least wise, that was probably 50k miles ago when I had it fixed.
More than likely, the mechanic was an idiot and it was only .5 qts low, as i'm 99% sure that they left the pinion nut loose when he did the job. (had a terrible vibration that mysteriously went away when i brought it back for them to find out what is going on .. they said they didn't do anything, but it was fixed when i got it back ... they don't get my business anymore)
Anyway ... would i be able to feel that clutch chatter with one rear wheel in the air and the trans in neutral? Assuming the worst case scenario, and the TC clutch is going out, how big of a deal is it? Can i get another 20K-30K out of it before it gives up the ghost?
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I had my truck at the shop today and it was determined that the transfer case front driveshaft seal is leaking and the gasket between the transmission and transfer case has also failed. The shop wants a reasonable amount to fix it but they need the truck for 2-3 days. It doesn't appear to be that difficult of a job to remove the transfer case. Am I missing something? Dropping off the truck and leaving it for a few days is the difficult portion......if they could do it in a day I'd just pay them and be done with it. So my thought was to pull it and just drop it off so they can replace the seals and fix any other issues.
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I just changed transfer case fluid on my father's F-350 for the first time in 13 years. (over 230k). Removed fill plug first and fluid gushed out of the fill hole unexpectedly. Did not have catch pan ready, so made a mess. I thought it was just over filled form the factory, but too much was coming out to be simple overfill. Almost 2 qt came out of the fill plug.
Did some google search and found many Ford trucks have failed transmission output shaft seal and transmission fluid leaks out to transfer case, causing transfer case to overfill. I am yet to check transmission fluid level, but considering how much came out of it that probably is the case.
Now, how bad of the problem this really is? Will overfilled transfer case cause some serious problem? 4x4 is rarely used (once or twice a year in winter) on this truck and from what I understand transfer case doesn't really do anything in 2WD other than just passing output from transmission through.
There are no fluid leaking outside and repairing the seal would be a too much of work for me.
Also changed rear differential fluid for the first time and I was surprised how clean the fluid was. There were thin layer of black sticky residue (sludge?) covering everything, but the fluid itself looked clean and no visible metal shavings. I guess that is why Ford said it does not require change under normal condition.
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Made a short run to get lumber yesterday and when I got home the truck smelled hot I checked it out and found a transmission oil leak at the rear of the transmission in front of the transfer case. can not really see what is leaking only has 22,000 miles. What may have happen. 2011 F250 4x4 6.7....
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I have a 97 jetta trek that is having problems. Grinding noises from transfer , no reverse, hard to shift, loud winding noise. I think it's may be the trough out baring thing from what I'm reading.
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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.
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I 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...
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Where/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
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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.
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Swapped 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.
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So 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.
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I 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?
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The dang thing leaks from the fill plug, I been reading about using liquid teflon on it.
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I had sold my Explorers but just picked up a 2000 Excursion V10 plow truck. It has been hacked and slashed I find cut wires under the dash and hood. I have tried everything to get the 4x4 to engage and no luck. It is used just for my driveway no road driving...
So question is: Can I engage the 4x4 at the transfer case so it will go, and stay in 4 wheel drive. If so do I take the shift motor off or does that big bolt by the motor do anything.
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I keep getting a check engine wrench on the readout, put a scanner on it and got the following code:
P183b transfer case code ...
What this means?
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My 4WD sport trac was running fine. I took it off road and put it in 4WD. After I was done in the woods. I put it back into 2WD and backed up to unlock. I then drove 2 hours home. The next day the transmission started shifting funny, especially overdrive almost like I was low on fluid. (which I check and I'm not) And the truck sounds like its running ruff. Is my transfer case still ingaged? Do I need to take it in for tranny work?
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