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I had to unplug the transfer case wires. The explorer kept putting it in 4 wheel drive every time I drove it and when it did the front end would bind and the truck would jump up and down when I turned it. This would happen so bad just backing out of my driveway that I though something was going to break.
I unplugged it a year ago and don't know where to start. Don't know why or what sensor is telling the transfer case to engage for one. For two I don't know why the front end is binding up so bad. Maybe a cv joint? I crawled under it the last time I did the brakes and rotated the front axle and drive shaft and didn't notice anything wrong.
Are your tires of a different diameter. This can be due to wear, inflation, or simply different sizes. If so, the 4WD will engage as it see's a different speed between the front and back. (Check the simple stuff first). This would also cause the binding you describe on a hard surface, as the traveled distance per revolution of each end would be different.
Controltrac, i am assuming from the problem described, you either have a sticky clutch pack or the hale sensors are sensing a rotational difference between the front and rear shafts.
1. check circumference of tires as already mentioned,
2. pull Hale sensors and clean/replace them,
3. drain and refill T/C with fresh ATF.
the hale sensors are at the rear of the T/C, they are secured with 10mm bolts, they are plastic so twist them back and forth to loosen, clean them and check for cracks in the sensor, they may be ok even with the cracks so reinstall and try.
Disconnect the negative battery terminal before you start (resets confused puter).
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