hello.

I have a 97 Explorer, 6 cyl, automatic, 4x4.

My truck is "clunking" during normal driving. It sounds like is coming from right under me or in the front. I replaced the transfer case in May with a new one. I cant make it "clunk", it just does it whenever it wants to. Usually under load. I have had it to 3 different tranny shops and they have inspected all the u joints, shafts, fluids ect and are telling me that they dont know for sure but think it may be in the transfer case. I have to ship this transfer case back to get a new one if that is it but if wrong I will incur all the shipping costs and be without my truck for a week or so.

If anyone has had a similar issue and solved it could you please let me know?

thanks,
Joe

 

Did you check the radius arm bushings? Mine are wore and clunk randomly over different bumps but mostly when turning.

 

For flytripper's references, here's a pretty nifty little diagram of an Explorer radius arm (check that it covers your model).

I may not be reading the description correctly....but a 97 Expy may not have radius arms.

Autozone's website it getting pretty handy...

http://www.autozone.com/servlet/UiBr...3d800c7471.jsp

 

No RABs on Explorers since 1995.

Mason

 

I believe the 97 Explorers 4WD selector switch options were 2WD, A4WD and 4WL. If this is the case, do you get the clunk in 2WD? If you do have 2WD and you get clunk in this mode, it is unlikely that you have a t-case problem. On the other hand, if you do have 2WD, and you get the clunk in A4WD only, the t-case could be causing the clunk, but might only be a symptom of another problem. This t-case has an electromagnetic clutch that operates off a Pulse Width Modulated dc voltage with a 50Hz duty cycle. In A4WD, the duty cycle to the clutch coil is 4%,(under normal conditions). This takes slack out of the driveline so that when conditions change and you need 4WD, the torque applied to the front output shaft does not create a clunk in the driveline, (probably not unlike what you are experiencing). So in effect, it just tightens up the driveline so you don't get clunk when you need 4WD. However, Ford had a number of complaints of driveline clunk and "shutter" around 96 and 97, maybe even 98 , I can't remember. But you wouldn't get clunk in 2WD mode because there was no voltage to the clutch coil and the clutch plates were allowed to slip, thus creating only minimal drag on the front driveline. However, in A4WD, the 4% "touch off" voltage could sometimes be enough to create a build up of torque that would suddenly release when it was great enough to overcome the static friction of the clutch plates. In later models, Ford reduced this voltage to 2%, and subsequently solved the problem. I believe that a dealer may be able to do this, it's only a program change in the GEM module, and shouldn't take but 5 minutes if they have the equipment. Also, make sure your tire pressures are all the same and you have fairly even treadwear on all tires. If the front or rear tires are able to rotate at different speeds, as in a turn, this can cause the torque build up on the front driveshaft that causes the clunk.

 

I replaced the transfer case with a new one and the problem is gone. Another bad Tcase this makes 4 in 5 years. The company I ordered it from, Transfercase express is still determining if this will be a warranty replacement or not. The have already charged my credit card for the new one pending the examination of the old one. The owner, Vern, said that if it is in fact the transfer case he will even pick to rental charges I encurred. I am still waiting for a answer. Vern is on Vacation and not able to look at it yet.

If anyone else has had dealings with transfercase express let me know how your experience has been. If they replace the case at no charge and pick up the rental then I will rate them high if not Buyer beware. I will let you know.

thanks,
Joe

 

Based on what you have said, I'm going to say with about 99% certainty, (gotta leave the door open), that Vern will find no problem with the T-case. For your sake, I hope I'm wrong.

UK

 

We had our tranny replaced and went through 3 t-cases ourselves in our '93 Explorer. I'm having problems now, but the warranty was up after 30 days, and it's been a year. I just don't think they make them very well. I do, however, love my Explorer. It's pretty dependable and doesn't cost us too much to fix. Angel

 

In response to Bronco2angel this is my 4th case as well. There are some problems with the case and a good rebuilder will resolve these during the rebuild.

Transfer Case Express has come through for me. They refunded my 2nd case purchase as the first WAS covered under warranty. Thats 695 back in my pocket. Plus the owner had mad a vebal commitment to pick up my rental car charges and called me to ask that I fax the rental reciept to him and he will cut me a check for that as well. I believe they have a new policy in place to pick up labor at a local shop if its there fault instead of the rental car but you will have to check with them on this. I WOULD HIGHLY RECOMMEND THIS SHOP TO ANYONE BASED ON MY EXPERIENCE.

I AM TRUELY A HAPPY CUSTOMER.