On my 95 explorer 4x4 (4r55e trans. Borg/warner transfer case) I seem to get a grind with a slight slip or shudder when going from 1st to 2nd. Every time I check GEM codes their is none! It got so bad one day it ended up breaking the shift fork in the transfer case. This is intermitten. It does not happen every day. The fork was replaced. My trans mech. said it should be ok. Well its not. It lasted one week. Now its started to do the same thing. I am a mechanic, but not a ford trans. man. This elect. shift trans is driving me nuts. No codes. I even went Mobil 1 full synthetic trans. fluid in transfer case, and still doing it. My trans. man can`t fix it. Seems to me now more of a trans. slip prob. than transfer case? All connections were cleaned. Any more ideas? Please help if u can. This happens in 2wd,4wdh and 4wdLow. Also, what`s the proper way to check this trans. fluid? Cold or Hot, or warm?

 

you should always check the transmission fluid at operating temperature and manually select all gears then back to park and check fluid level.

you have a lot of information here and it is somewhat confusing. if you have a trans problem with first and second, I would check the valve body gasket around the low/reverse servo. you need to remove the pan and the servo is at the rear of the trans. the condition you described points to a gasket problem that was very common for this trans.

did you break the shift fork while in 4x4? I guess I just need more info.

 

Did you ever find out your problem, I'm working on a 97 F150 with similar trouble. The friend that was driving it said it would shudder when taking off. I have it out now and I am sure it is a T case problem, but I have not cracked the case open yet. I will be opening it up soon, but would really like a manual on it. I am also a mechanic ( generators) but have not done one of these before.