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Damn this A4WD. It feels like the front wheels just keep binding. Especially when there is a load in the vehicle or even when just going up a hill. Really really sucks.
Assuming no problems with the shift motor, I would look at the age of the transfer case fluid as a potential culprit. I had a similiar, but less severe problem in my '99. Ford dealer checked out the (non-limited slip) differential, took apart the front axle and diff, found nothing. I suggested that it felt like the transfer case had 4HI partially engaged. Skeptical service manager contacted the company, company rep said flush the transfer case a few times with new fluid, problem went away.
Provided you are not loosing traction then the system is passive. So it might be engaged for the wrong reasons. Also if nothing else helps your situation you could always pull the fuse or add a switch as others have done.
Changed any tires lately? If the difference in the diameters of the tires varies by too much (I don't know what too much is) the A4WD can engage under otherwise normal driving conditions.
Not sure about Ford transfer cases, but Jeeps have a viscous coupler (VC). The VC is liquid filled and when they go south the vehicle is in 4wd all the time. Sometimes by changing the fluid in the differentials and the transfer case to synthetic fluid solves the problems by keeping fluid temperatures down. As someone else suggested, it make take a couple of fluid changes.
Personally speaking it didn't work for my Jeep. I had to buy a new VC.
Last edited by 2Fords1Jeep; May 3, 2005 at 07:14 AM.
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