Okay,so definately this is mechanical...the RBC is screwed!I got a hold of a parts store(Genuine Ford Parts.com)they had the cheapest price...340.00$..but they call it an"electric differential clutch assembly"...I asked him if it was the assembly that bolted on directly in front of/on to the diff. assembly and he said yes...it sounds like the correct part...he had not heard it reffered to as an RBC though...so I guess that's where it's looks like it stands as far as what I have to do...replace the RBC...the vehicle only has 60,000 on it,and from my research it sure doesn't sound like something that happens often...but,not much I can do but replace it...thanks so much for the help/advice...VERY much appreciated...Brent

 

OVE 1...one more question I forgot to ask,and I'll ask this the best way I can..how "seperate" is the RBC from the Diff.?for example,the RBC is connected to the Diff...how I don't know,but when you remove the RBC,what seperates it(ie:the RBC internals...fluid,etc...)from the diff.?there has to be a shaft/gearing of some sort from the RBC to where it connects to the diff when 4x4 is kicked in...for example,does the fluid level in the diff. have any effect on the RBC?sorry,this might seem like stupid questions,I know what I'm thinking,I just don't know how to put it into words...Brent

 

You have mail.

 

Just thought I would update on my problem...i changed out the RBC...that was the problem...it locks up in auto(when needed)and locks up now manually when I select manual mode...not too difficult a job...was surprised to see the RBC was totalled destroyed...bits of metal everywhere...the whole top of the RBC had come apart...no wonder there was no 4x4...I just bought it, so I don't know what the previous owner did to it,or if it was even his fault...but there was nothing left of that RBC...

 

Glad to hear that you were able to replace it and fix the problem. It may have been destroyed if it was towed with the front wheels up and the rear wheels on the ground without disconnecting the drive shaft.

Any how-to tips to share?

 

If it was shattered like you describe, it probably was an impact of some kind. Towing would only burn up the insides, I would guess.

 

An impact would damage the casing around the RBC...there was no damage to the aluminum cover/casing at all...

 

Boy...do I have all the luck...when I posted the last time to say it was fixed,I never really took it for a good test drive...that was when the problems started.We got the new RBC in and did it ever make a racket...really bad 'growl' type noise...we checked everything we did and could not figure out what the problem was...so we finally decided it must be a faulty part...It didn't seem likely,but we didn't know what else to do...so I ordered another one...the parts supplier said they would take back the old one and ordered a new one.We put the new one in and it works great...no noise.When we took the 'new' one back out,and put it on the bench,we spun the 'inside' of the RBC and you could tell something was wrong,it sounded like an internal bearing making a 'growling' noise.So now,the 4x4 works in auto and manual mode,and makes no noise,nice and quiet.Obviously it was the 'first' new part.As far as tips...the replacement went quite well...took about 2 hrs(of course now i'm a 'proffesional,I took it apart 3 times...I could do it with my eyes closed)...I drained the oil from the diff...driveshaft comes off,(u-joint bolts,center bearing nuts...I left the bolts holding the front of the driveshaft to the transmission and just supported it with some wire)then the RBC housing comes off(6bolts)...then the RBC itself just slides off the splined shaft(also have to undo the wiring harness at the top of the housing)...once you get it on the bench,you can remove the yolk...you also have to remove the splined shaft from the old RBC (that the yolk fits on) and install it onto the new RBC(4 bolts)install the reverse of removal...after you get it all back together you refill the diff. and away you go...pretty straight forward actually.