I have a 1994 aerostar AWD van with 130,000 miles. The transfer case was reworked under a recall by the ford dealer by preious owner just prior to me purchasing it. There has only been 2,500 miles additional right now. No I am not 4 wheeling, My driveway is the problem. I transfer chain sounds likes its jumping a few teeth just rolling in the driveway. Also the is alot of vibration between 55-65 mph. Hit 70 its settlesdown. Because of physical limitations I ask my 25yr old nephew to craw under and take a look. he saw at least 3 cracks in the housing around the front drive line. It apears to be a dana TC28 according to my internet lookup. At this time I can't afford a rebuilt transfer case with the core charge because it is cracked.


Here is my questions: Can the transfer case be removed and some kind of spacer kit that can attach to the transmission and reconnect the rear drive shaft and completely?

Can the TC28 be modified to be manual engagement rather then electronic? I only need it on the snowy days just to get out of my 1300 ft uphill driveway.

Is there a transfer case by another manufacture be used in its place? What other ford vechicle that has TC28?

Any words of wisdom on getting another xfer case (online or junkyard) ?

I always thought DANA had a good rep but I am starting to wonder about the aluminum transfer cases.

 

car-part.com

 

wjeffres,

It sounds like someone did a lousy job working on your transfer case. The easiest fix would be to try to replace it with another one of the same model, either a rebuilt or from a salvaged van.

About manual engagement, you might be able to intercept the power lead oging to the electric clutch, and wire it to a switch on your dash. I'm not sure how the computer will react to that.

Or, you might be able to find a fully manual xfer case from a Ranger or Explorer that will fit. You will have to install the shift handle somewhere.

 

I saw a transfer case with low mileage being sold on ebay. You may want to check it out. Search under Aerostar.