T-case issues.. AWD guys help!
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Freshman User
Joined: Nov 2004
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T-case issues.. AWD guys help!
So yesterday I noticed a whooshing/whining sound that I suspect is coming from the T-case, but no drivability issues have arose, runs and drives beautifully. Today I managed to check the level of fluid. When I pulled my finger out of the fill hole, it was red... is there any possible way that trans fluid could leak into the T-case? I've had plenty of work done to the trans, so a mechanic might have drained and filled it at some point. if not, is it ok to use mercon in the t-case? or should I try draining it and puttin in some 80w90? Or could this even not be related to the noise I'm getting?
Thanks in advance! 92'AWD with t-case lockup switch installed, AWD module bypassed.
Thanks in advance! 92'AWD with t-case lockup switch installed, AWD module bypassed.
Postmaster
Joined: Sep 2003
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From: Southern California
The Aerostar Transfer Case uses Mercon, not the usual gear oil. So what you saw was correct. If you can feel it with your finger, the level is correct and nothing is amiss. Now you can sleep well at night 
P.S. The front differential also uses Mercon. The only thing using gear oil is the rear differential.
P.S. The front differential also uses Mercon. The only thing using gear oil is the rear differential.
Postmaster
Joined: Sep 2003
Posts: 4,452
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From: Southern California
About the noise, it's best to take it to a shop so they can raise it on a hoist and listen. Most shops will do this for free. If not, raise all 4 wheels off the ground by jackstands, put the van in D and listen. Without being there, I can't say what's causing that noise.
Junior User
Joined: Oct 2005
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most cars are not designed to be driven with no weight load.
If you drive too fast you will destroy your differential/gear box etc.
If you drive too fast you will destroy your differential/gear box etc.
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Senior User
Joined: Sep 2004
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From: brooksville, florida
hey guy's I have a good used t-case from a 1992 4wd explorer that I thing will fit the areostar, now I know this not the place to advertise but I am sure just a little add wont hurt will it, I will send it any place so long as the shipping is payed give me a call on 352 597 8888 for price it's going to be real cheep because I can't use it.
P.S. hope I don't get a telling off for this, I just would like to help out a fellow aero owner.
P.S. hope I don't get a telling off for this, I just would like to help out a fellow aero owner.
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Senior User
Joined: Feb 2004
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From: Rochester, NY
Originally Posted by Ray_N
most cars are not designed to be driven with no weight load.
If you drive too fast you will destroy your differential/gear box etc.
If you drive too fast you will destroy your differential/gear box etc.
For starters, why would you drive fast on a lift just to diagnose a noise? Beyond that, no load on the drivetrain means that no stress and strain is occuring. No impact occurs. That's a pretty easy condition for a geartrain, its when you force them to operate loaded, especially heavily, that wear can occur...
Postmaster
Joined: Sep 2003
Posts: 4,452
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From: Southern California
Originally Posted by cbr900
hey guy's I have a good used t-case from a 1992 4wd explorer that I thing will fit the areostar, now I know this not the place to advertise but I am sure just a little add wont hurt will it, I will send it any place so long as the shipping is payed give me a call on 352 597 8888 for price it's going to be real cheep because I can't use it.
P.S. hope I don't get a telling off for this, I just would like to help out a fellow aero owner.
P.S. hope I don't get a telling off for this, I just would like to help out a fellow aero owner.
Posting Guru
Joined: Jun 1999
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From: Northern California
Copper, I talked on the phone with a friend who works at a Ford-Mercury-Lincoln ONLY dismantling facility** (** = "JUNK YARD"!haha) He said the EXACT SAME thing as you, without hesitation. Then, later I get online, and read your post! CBR900, I am glad to see good people like you trying to help out, no question about that! Ed ...
Postmaster
Joined: Sep 2003
Posts: 4,452
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From: Southern California
Originally Posted by Ed
Copper, I talked on the phone with a friend who works at a Ford-Mercury-Lincoln ONLY dismantling facility** (** = "JUNK YARD"!haha)
Hey, now I know who to bug for hard to find parts
Postmaster
Joined: Apr 2001
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Under the "For What's Its Worth" category, I have tried running my AWD while all four wheels were off the ground, trying to diagnose similar problems. After doing so, I would not recommend this. The poor old transfer case solenoid goes crazy trying to figure out what is going on. Things are engaging and disengaging, sometimes all four wheels are turning, other times only one or two are moving. The clunking, clanking and carrying on makes it all but impossible to find noises. Trying to crawl around under a van with all those wheels and shafts in motion is an extremely dangerous proposition. In the end, I found nothing of substance for the torture inflicted on my old van.
Senior User
Joined: Feb 2004
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From: Rochester, NY
That I'd believe. If there's more drag torque on one end then the other, that'll make one axle spin before the other and the clutch will try to even things out. Makes sense, but I doubt it would really actually hurt anything, as long as it doesn't cycle continuously for an extended period of time. Sounds like a good way to check to see if the clutch is working properly though. But I agree, you don't want to be crawling around under it while the wheels are deciding whether or not they should be turning...
Postmaster
Joined: Sep 2003
Posts: 4,452
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From: Southern California
Originally Posted by aerocolorado
Under the "For What's Its Worth" category, I have tried running my AWD while all four wheels were off the ground, trying to diagnose similar problems. After doing so, I would not recommend this. The poor old transfer case solenoid goes crazy trying to figure out what is going on. Things are engaging and disengaging, sometimes all four wheels are turning, other times only one or two are moving. The clunking, clanking and carrying on makes it all but impossible to find noises. Trying to crawl around under a van with all those wheels and shafts in motion is an extremely dangerous proposition. In the end, I found nothing of substance for the torture inflicted on my old van.
Very funny description, Aerocolorado. But I was thinking more along the line of disconnecting the AWD computer under the seat before you do that, if you're only trying to listen for worn gears or whatnots on the transfer case. Also, I'd recommend putting the poor thing on a real lift at a shop, where they support the front ends at the lower control arms.