Hello!

Sorry to bother with stupid questions, but I am completely stuck with the problem.

I own 2000 Expedition with engine rebuilt recently.

There was no problem with axles before engine was rebuilt, but then it started to behave like it has all differential locked. Steering more than a little make wheels stuck and when i lift one of them - I see drivetrain got released (wheel spins).
Also vehicle turn make clicking sounds in front axle.
4WD switch make no sound between A4WD and 4H, except sound of switching relays. However 4L works well.

Don't know exact numbers of axles, but front axle seem having no electrical connectors, but rear one has a connector on a diff top (is it e-lock?)

Couldn't find any information on diff e-lock and what module make it stuck, can you point me out?

And also - can it be tied to non-working ABS?

 

The connector on top of the rear differential is the ABS wheel sensor. There is no locker feature for either axle. To me it sounds like your transfer case is locked in 4Hi.

Remove fuse #104 from the fuse box under the hood to see if the locked feeling goes away.

 

Removing fuse made it turn easier at last - what does that mean?

 

I've finally checked on concrete floor - turn, going forward a little - wheels stuck and lifting make a release. Seems fuse absence don't work as it should.

I also forgot to mention about bumps under floor that I feel when I move forward. More acceleration and less speed - harder bumps happens.

Any ideas?

 

Since removing the fuse didn't make a difference, then the problem is internal to the transfer case. The TC will have to come out and be disassembled for diagnosis. In the meantime, you can remove the front drive shaft in order to drive the truck without doing any damage to it.

 

Agree with Alloro. Based on the descriptions, the transfer case seems to be having internal issues. It could be a bad internal relay that is causing the transfer case to refuse to unlock.

As for locking diffs, the Expedition only has one locking differential, the center one inside the transfer case. And it seems to be locked-up continuously which is causing your problems.

The 1999-2002 model Expeditions had a two-speed dual range BorgWarner 4406 transfer case with an intelligent locking center multi-disc differential. It’s called a multi-disc differential for it is an electromagnetic multi-disc clutch pack with multiple clutch plates and friction discs. There are no planetary or beveled gears, but yet it allows the front and rear drive shafts to turn at differential speeds in Auto mode, even while torque is being transferred to both axles.

In Auto mode, its unlocked for a variable torque split. In Four High and Four Low modes, its fully locked for a 50:50 torque split. Yours seem to be stuck in Four High.

 

To add to LocDoc's post, we have the 4406 TOD in the 99-02 Expedition. You symptoms mirror what I went through about 3 years ago. Alloro was a big help in trying to chase down the gremlin, and like he said above I had to drop the TC and break it open. The clutch pack basically disintegrated.

Check this site for ordering the exact arts you need once you diagnose ...Borg Warner 4406 Torque on Demand Transfer Case - Rockland Standard Gear, Inc.