2004 Explorer Drivetrain Slam

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Aug 18, 2013 | 09:27 PM

MitchPeters

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From: Alexandria, Ohio

2004 Explorer Drivetrain Slam

My '04 Explorer started making a noise like slamming in and out of gear. Felt and sounded like the transfer case was slipping or jumping teeth. Turning slow in gravel the left rear would drag like a spider gear problem.
It has the Auto 4x4 system, Auto-4H-4L.
I pulled transfer case out and apart. No signs of teeth missing, slipping, nothing. Chain looks good, bearings good. Clutch pack good. No sign of any metal shavings in the case.
Pulled rear differential, one bad spider gear for the left axle is all I found. Not enough for the very hard slamming it was doing.
U joints & axles good also.
Any ideas?

Aug 18, 2013 | 10:07 PM

shorod

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From: Cedar Rapids, IA

I was going to question u-joints. You mention they are good. How did you confirm they are good?

-Rod

Aug 19, 2013 | 01:13 AM

MitchPeters

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From: Alexandria, Ohio

No Movement in neutral. Both are on the floor along with rear axle shafts. Noise way worse than a u-joint

Aug 19, 2013 | 06:48 AM

shorod

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From: Cedar Rapids, IA

I wonder if it's an issue with a sensor somewhere that is making the transmission think it is under more load than it and firming up the shifts. I recall a parameter in the scan tool for "harsh shift requested" with a Yes or No response. It would be interesting to see what yours is showing.

-Rod

Aug 19, 2013 | 05:39 PM

sandrat

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From: Back where I started...

Sounds like a solenoid body in the transmission. There was a bulletin for this concern, did a lot of them back in the day. Especially bad in reverse? There's a delay, and then it drops in really hard?