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This Problem has occured since new, and could never be diagnosed as it only happened when the vehical was driven in hot weather for long trips. Now it occurs quite freqently during hot weather.
When turning a corner, one of the wheels would bind, then release. The dealer cannot find the problem. I unplugged the AWD fuse, and the problem goes away, so I assume it is electrical. I have for the past couple of years unplugged the fuse in the summer and put it back in the winter. Will this cause any problems doing this? The dealer says he has never had this problem before.
My 1995 Aerostar does this too. If I unplug it, it goes away. You might need to replace one of the speed sensors on the transfer case. I pulled both of mine out and the rear sensor is bad. If the sensor looks damaged or "worn" it might be more than just the sensor that is worn. Something inside of my t-case has enough play that it hits the sensor under load. I haven't replaced the sensor yet because I am going to have to get the transfer case rebuilt first.
As far as unplugging it in summer and then re-plugging in winter, I would not let it sit all summer without being plugged in. I have other 4x4's and they recommend that you use the 4x4 at least once a month to keep everything lubricated. I also do the same on my Aerostar. I plug it in once a month and drive it for a day or so. Then I unplug it. I hope to have it rebuilt before winter this year.
If it only binds every so often it is probably the rear sensor. If it binds on every turn, it is probably the front sensor. Other problems such as bad grounds or bad wires\connections will also cause the t-case to lock up.
Does pulling this AWD fuse turn an all wheel drive Aerostar into a rear wheel drive. If so wouldn't it make sense to put the fuse in for bad weather driving conditions only and just run the rear wheel drive for dry roads?