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My 93 Aerostar AWD will occassionally exhibit the following behavior when driving at about an hour at highway speeds. The will be a low level vibration from the the front end for about 2 seconds. Steering will drift to the right slightly. It seems like a disproportionate amount of torque is going to the front axle. One the probme starts, it will reoccur every few minutes. If I stop and pull the fuse for the AWD microprocessor, the problem disappears. However, I suspect I am not running power to all four wheels. Any ideas?
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Sounds like your problem may be a function of the time it takes certain drivetrain components to warm up and change chacteristics. It could be one or both CV joints beginning to bind and thus altering the sensory input to the processor that controls the AWD. Removing the fuse aborts this. Check the boots on the CV joints. Split boots allow dirt to get in and lubrication to get out. While you have the front end up, check the U-joints off the transfer case. Any slop in the U-joints is bad news. It could also be in the transfer case itself with a loose chain/gears. Check also the upper mounting bracket on the front differential - these are known to crack and allow the differential to come down and rest on the crossmember. This will allow the case to flop up and down and again alter the torque to the front wheels. Search past postings on this board as many others have had AWD problems of one sort or another. Mine would lock up when backing out of a parking space. The connector on the AWD processor under the drivers seat was loose. Good luck!
If the problem isn't mechanical, it could be a short to ground that's causing the transfer case clutch to engage when it shouldn't. Or it could be a bad sensor or possibly even something wrong with the 4WD module. Pull out the wiring diagrams and check for a short to ground between the transfer case clutch high and low pins.