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I have a 94 aerostar and have the 4wd module unplugged. My question is, why do the rear wheels spin as much as they do on ice. I know that 1/3 front and 2/3's rear power, but isn't that enough to control the rear end better? I can break the rear end loose quite easily and I thought that wouldn't happen. What's in the transfer case that divides the power a chain? or something else.
Thanks
The transfercase has a planetary differential which divides the torque. It mechanically sets torque split; one third to the front and two thirds to the rear. The only time the electronic control is needed is when a wheel completlely loses traction, then the transfercase locks briefly sending torque to the opposite axle. The transfercase differential reacts the same as a standard differential in any front or rear axle. It is just placed "between" the axles. As such, if a wheel (or axle) completely loses traction, there is no way to send the torque to the opposite axle. This is where the transfercase clutch (controlled by the electronic module) comes in. When a wheel loses traction, the clutch locks the differential up like a "posi" and sends torque to the axle with traction.
If your sensors and/or module have gone bad and you don't want to spend more money to fix them, then providing your clutch is still good, you can hook a "momentary" push button switch directly to the transfercase clutch. It takes 12 volts and about 6 amps. If you are stuck and spinning a tire, push the button for added traction.
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The problem I'm having is, the idiot light doesn't come on at all. I replaced the control module and the light comes on but when the 4wd tries to kick in the fuse blows. So the clutch is no good. Is this a solenoid or something else? There is no error code flashing the light will come on at startup and the for half a second as the clutch tries to engage but then the fuse goes.
Sounds like there is a short somewhere. Maybe in the clutch wiring. If you can, go to a local dealer and see if you can look at the service manual section for the EAWD. This describes the wiring and various checks to perform to find shorts and open circuits. As far as what the clutch is... it's basically a big coil magnet like they use at salvage yards to lift steel. It is set up to squeeze a stack of clutch plates when energized. The clutch plates act like a "posi" or "locker" and help send power to the wheels with traction. Good Luck.
Thanks Aerostar1 That gives me a better understanding of the transfercase. I couildn't find any detailed info on it. I have a full size bronco and have always found all the info I needed on it but not for this unit.