96 explorer transfer case sensor? part? leak
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96 explorer transfer case sensor? part? leak
96 exlorer 4x4 control trac (electronic) w/ 4.0 engine. (Long post-sorry)Question:
On the rear of my transfer case (Borg warner 4405) to the left of the rear driveshaft there is some type of switch? sensor? with 3 wires (blk,red,grn) comming out of it. It is somewhat oval shape with one bolt attaching it to the transfer case on the lower edge of the oval. The wires pass thru the top portion of the oval. This switch/sensor is leaking red fluid at the bottom, area. I tried to tighten, still leaks. I removed the unit (maybe 2"tall 1" wide and 1" deep) and found it to be hard black plasitc completely enclosed where it enters the fluid side of the transfer case. It is mounted slightly above the normal fluid level. There are no gaskets and no gasket sealer present, the unit just seems to slide into the aluminum casing. Can anyone tell me the part name of this unit and what might be needed to stop the leaking. I don't see any damaged parts and it is not leaking where the wiring passes thru it. Any help would be appreciated. (I have a digital photo of the unit on the truck but don't know how to post it)THANKS!!
On the rear of my transfer case (Borg warner 4405) to the left of the rear driveshaft there is some type of switch? sensor? with 3 wires (blk,red,grn) comming out of it. It is somewhat oval shape with one bolt attaching it to the transfer case on the lower edge of the oval. The wires pass thru the top portion of the oval. This switch/sensor is leaking red fluid at the bottom, area. I tried to tighten, still leaks. I removed the unit (maybe 2"tall 1" wide and 1" deep) and found it to be hard black plasitc completely enclosed where it enters the fluid side of the transfer case. It is mounted slightly above the normal fluid level. There are no gaskets and no gasket sealer present, the unit just seems to slide into the aluminum casing. Can anyone tell me the part name of this unit and what might be needed to stop the leaking. I don't see any damaged parts and it is not leaking where the wiring passes thru it. Any help would be appreciated. (I have a digital photo of the unit on the truck but don't know how to post it)THANKS!!
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Nothing I saw when I took it off, I will give a closer look. I did visit the Saturday Ford parts guy, but he wasn't much help. said he thought it was a part comming from the shift motor. But the schemadic drawing didn't support that. He didn't know what the part was and said it wasn't listed?? I will check with the regular guys or another dealer during the week, I guess.. Thanks
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I think that it is the transfer case shift motor connector. Go to a parts store's website, like Rock Auto or NAPA, and look up the transfer case motor. There's a connector attached to it that sure looks like the one you described.
I took a look at the Ford factory manual, and this connector is on the rear of the transfer case, to the left of the driveshaft like the one you have. It does have a retainer bolt. The connector has 16 cavities and a 14 wires attached to it. Are you sure that yours has only three?
The diagram in the manual shows a "wire connector locking sleeve", and cautions against damaging it. Take a close look at the connector. Does anything look broken? If not, you might try using some Permatex 2 sealant on it before reinstalling it. If it is broken, you might want to get one from a boneyard.
Otherwise, I think your two choices are to live with the leak, or replace the shift motor (about $80). I'd live with the leak myself before I'd drop $80 to replace a motor that works fine.
Good luck!
I took a look at the Ford factory manual, and this connector is on the rear of the transfer case, to the left of the driveshaft like the one you have. It does have a retainer bolt. The connector has 16 cavities and a 14 wires attached to it. Are you sure that yours has only three?
The diagram in the manual shows a "wire connector locking sleeve", and cautions against damaging it. Take a close look at the connector. Does anything look broken? If not, you might try using some Permatex 2 sealant on it before reinstalling it. If it is broken, you might want to get one from a boneyard.
Otherwise, I think your two choices are to live with the leak, or replace the shift motor (about $80). I'd live with the leak myself before I'd drop $80 to replace a motor that works fine.
Good luck!
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From: Plymouth USA
There should be an o-ring on the sensor. Mine leaked to and I just wiped off the sensor best I could and added a thin coat of RTV sealer then reinstalled. Don't tighten the bolt to tight. So far no leak.
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Took a closer look and found there was a O ring. It was flatten and smooth and hard to spot. Anyway, changed it and am now on to another fix! Thanks everyone.
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How do you pull wires out of an old connector w/out damage to put into a new part?
I am changing out the 4x4 transfer case motor on my 97 expedition. The new part comes with and electrical connector with "open" holes for wires to be added. How do I get the old part off without damaging the wires that need to be moved from the old connector to the new one?
Do I just crack open the old connector and then the wires, once free, can be pushed into place on the new part?
THANKS!
Do I just crack open the old connector and then the wires, once free, can be pushed into place on the new part?
THANKS!
Originally Posted by kevin74656
I think that it is the transfer case shift motor connector. Go to a parts store's website, like Rock Auto or NAPA, and look up the transfer case motor. There's a connector attached to it that sure looks like the one you described.
I took a look at the Ford factory manual, and this connector is on the rear of the transfer case, to the left of the driveshaft like the one you have. It does have a retainer bolt. The connector has 16 cavities and a 14 wires attached to it. Are you sure that yours has only three?
The diagram in the manual shows a "wire connector locking sleeve", and cautions against damaging it. Take a close look at the connector. Does anything look broken? If not, you might try using some Permatex 2 sealant on it before reinstalling it. If it is broken, you might want to get one from a boneyard.
Otherwise, I think your two choices are to live with the leak, or replace the shift motor (about $80). I'd live with the leak myself before I'd drop $80 to replace a motor that works fine.
Good luck!
I took a look at the Ford factory manual, and this connector is on the rear of the transfer case, to the left of the driveshaft like the one you have. It does have a retainer bolt. The connector has 16 cavities and a 14 wires attached to it. Are you sure that yours has only three?
The diagram in the manual shows a "wire connector locking sleeve", and cautions against damaging it. Take a close look at the connector. Does anything look broken? If not, you might try using some Permatex 2 sealant on it before reinstalling it. If it is broken, you might want to get one from a boneyard.
Otherwise, I think your two choices are to live with the leak, or replace the shift motor (about $80). I'd live with the leak myself before I'd drop $80 to replace a motor that works fine.
Good luck!
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Thanks for your help. By reading yours and other posting I figured out what I needed to do. Turns out I had to use pull out a red retainer out of the existing transfer case shift motor plug, then pull out seven wires, two sets of three and one sigle that are sensor leads that route through the plug. I pushed the old wires into the back of the new plug in their same positions. Pressed the old red retainer back into the new plug, and was able to reconnect the plug, install the new transfer case shift motor and now my 4x4 Lo and Hi both work again.
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