03 4.0L 3.73 LS 75,000 miles, I have a series of clunks (lack of a better way to describe it) during accelleration that you can feel and hear. It appears after longer runs or towing my 18' fish and ski boat. I have had the normal problems fixed on this Explorer, axle seal leaks, ring and pinion for rear end whine returned with 13,000 miles ford won't fix again, and recently rear wheel bearings and hubs. I have had the clunk for awhile but it has gotten much worse recently. Ford shop said it was a misfire in cylinder 1 and 2, but there was no check engine light on. Changed spark plugs and wires, no change still got the clunk. To me it felt like a tranny slipping, but the tranny tech at the dealer rode with me boat attatched and drove it and said the tranny felt very good. No problems at cruising speed, only during accelleration in mainly 1st and 2nd gear. Anybody else got this problem or idea on a fix? I hate paying the shop to hunt and peck to find the problem. Thanks for the help, Steve

 

Is this a control trac vehicle??

 

Yes unfortunately it is, I wish there was a way to lock it into 2wd only, and I asked the Ford shop if this was possible they said it couldn't be done due to the computer programming.

 

This is a common symptom of sticky clutch pack in the T/C, or uneven tire circumferance.

1. Flush the T/C and fill with clean ATF
2. Pull the HALL sensors (2) out of the T/C and clean them.
3. Check the tires, if there is a difference in circumferance or wear pattern, you will need to correct this (rotation and/or air pressure, replace).
4. If the tires are well worn/soft you may be getting torque slippage on the road, causing the T/C to momentarily lock.
5. Dragging brakes

On the good side, at least you know the Control trac is working...

 

1. Tranny and t/c flushed by ford 10,000 miles back.

2. Tires are brand new.

3. I will pull the HALL sensors and check the brakes.

I agree it feels like it is kicking into 4wd. Drives me crazy. I have had several problems with this Explorer but Ford has taken pretty good care of me and assisted in the larger repair bills. I would like to sell this and get an f150 that is better suited to pull with, but I got to find the problem first. Thanks for the advice.

 

we run a couple of them and have had similar situation, we use them for dive rescue first responder

 

I am assuming that the sensors are pretty easy to locate? If you pull them do you have to refill the transfer case? Are they both located on the transfer case itself? Thanks

 

The HALL sensors are both on the rear of the T/C, one above the rear shaft output and one between the rear output and the shift motor, 1 10mm bolt on each, twist and pull to get them out, snug pressure fit only.... NO need to drain fluid,...but check the level while you are down there, should be level with fill hole to the left of the rear output shaft.. 10min job.