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'99 Expy - AWD "stuck"

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Old Nov 5, 2012 | 10:34 PM
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'99 Expy - AWD "stuck"

Sorry about the crappy title....no other way to put it right now. Let me explain: '99 Expy with 153K miles. E4OD, AWD.

Out of the blue, when you turn it on, there is a clicking noise behind the AWD/4H/4L selector switch. No 4H or 4L mode is indicated on the dash. If you roll in a straight line, things seem OK but as soon as you turn the wheels, it's obvious that the 4WD is engaged and wants/needs the wheels to slip. Then it gets feeling 'bound up'.

I'm leaning toward the electronics that control the whole works being "tango uniform". I'd sure like to hear if someone has experienced this issue or what direction you recommend I pursue.

Thanks in advance.
 
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Old Nov 5, 2012 | 10:40 PM
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Yes there is an electronic control in the dash, but it's the shift motor down on the transfer case that controls everything. The various contacts which indicate the position of the motor are built into the motor. I'm more inclined to think there is an issue with the contacts.
 
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Old Nov 7, 2012 | 08:00 PM
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OK....I've taken fuse 104 (30A) out and it's still "bound up".

Would removing the motor on the transfer case be my next step? If it is somehow keeping the xfer case in 4H or L, will pulling the motor free things up?

I've searched and come across a couple different threads about this topic. It seems that nothing in those threads has helped.
 
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Old Nov 7, 2012 | 11:34 PM
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Originally Posted by TX76F250
OK....I've taken fuse 104 (30A) out and it's still "bound up".
In that case, the front clutch in the transfer case is broken. With fuse 104 removed there is no power going to the clutch so it should not be engaged. Since it's still binding, the only possibility is that the front clutch is mechanically jambed.
 
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Old Nov 8, 2012 | 06:52 AM
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Thanks Alloro....hard news to hear, I was hoping this would be an inexpensive (or relatively easy) fix.
 

Last edited by TX76F250; Nov 8, 2012 at 06:54 AM. Reason: parenthetical insert
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Old Nov 8, 2012 | 09:17 AM
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You can remove the front driveshaft for the time being. This way you can drive it until you are able to get it fixed.
 
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Old Nov 8, 2012 | 09:23 AM
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like he said if you dont plan on using 4 wheel drive remove drive shalt. if it is electronic 4 wheel it is probably shift motor but pulling it wont take it out of 4 wheel
 
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Old Nov 9, 2012 | 03:30 PM
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pulled the front driveshaft so the wife can run around in 2WD for now. Picked up a "new" xfer case @ a local wrecking yard.

Will keep ya posted.
 
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Old Nov 9, 2012 | 03:47 PM
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Originally Posted by TX76F250
pulled the front driveshaft so the wife can run around in 2WD for now.
I'll assume that made it drivable?
 
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Old Nov 11, 2012 | 08:55 AM
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It did. Took some pressure off too!
 
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Old Oct 22, 2013 | 11:32 PM
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Ever fix this? Same issue here.
 
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Old Oct 22, 2013 | 11:42 PM
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Negative. Still have the front driveshaft out.
 
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