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I just picked up a 2004 escape v6 awd with 83k super clean from the auction. On the way back abs was acting up so I order some new tone rings as I saw two cracked one. And then as I would hit higher speed it would feel like it sort of dropping out of gear or struggling to hold power and then sort of stuttering. I checked the trans fluid has no metal in it and fluid looks fine, checked the transfer case fluid is full but has metal in it! I pulled rear driveshaft to see if it drives better like that, drives a bit better but not much. Does it sound like a new transfer case would solve the issue or not since because still did it without rear driveshaft in? Thanks any input is appreciated!
Well, you already know the transfer unit is toast, it's going to have to come out anyway. Internal damage to the gears can and will cause "negative feedback" to the transmission even with the rear driveshaft disconnected. Just went through that last fall on the 07 Mariner.
Whether or not that's all that's wrong is impossible to determine. Could be lots of things that might cause your stated symptoms, for example, restricted exhaust or transmission issues.
Does it sound like a new transfer case would solve the issue or not since because still did it without rear driveshaft in?
If metal came out of the PTU the gears and bearings are probably chewed up. Damaged PTU
Driveshaft removal has greatly reduced load on the PTU but you are still grinding gears and wasting fuel, best bet would be to replace the PTU. You can find used units for ~$250 and hope there is no damage. Reman'd units are ~$650 with a core charge. Last time I checked, Ford wanted ~$1500 for a new unit. I would opt to replace the PTU ASAP. Since the PTU constantly spins if any metal pieces large enough get between the gears it can cause damage to the case, which would result in a non-refundable core charge.
FWIW, due to the 4WD/PTU function I don't think you will trip any codes as there really isn't a way for the vehicle to identify the missing driveshaft. Not unless you get lots of FWD wheel spin then the wheel sensors will taddle when they see the right front spin but no wheel movement in the rears.
If you do keep the Escape and replace the PTU, make sure to change fluid in it at 30Kmiles if not less. Use synthetic oils for better longevity. It's so little fluid in the PTU I just change it at every other oil change.
Here's the PTU I pulled from the Mariner. I was able to score a replacement for $80 from a local salvage yard that I found on www.car-part.com Pricing was all over the map.
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