I did a search on here but didn't find any information about this but has anyone had their transfer case chain replaced or the whole transfer case rebuilt? I'm pretty sure my chain is slipping in the transfer case. When I'm in A4WD or 4x4H I get a terrible metallic thumping/slipping noise coming from the transfer case area when ever it is trying to deliver power to the front axle. I just finished changing the transfer case oil and the front differential oil but it didn't fix the problem. If I remove the A4WD/4x4 fuse (basically putting the truck in 2 wd only) the noise doesn't happen. Just trying to get an idea how much it costs to replace the chain or rebuild the whole thing. BTW I have 192k on the truck.

Thanks

Nathan

 

It is highly unlikely that it is the chain. Unless the truck has spent a huge amount of its life in 4wd, chains just do not wear out. I would guess that something in the engagement mechanism is failing. It could be as simple as the shift motor not fully engaging. That is where I would start.

The other option you have is finding a used t-case in a salvage yard. That would be much cheaper and easier than a rebuild.

When you changed the fluid, you would have found tons of metal, most likely sizable chunks, if the chain was jumping. How did it look?

 

Check out the answer in post #6 of this thread:
https://www.ford-trucks.com/forums/9...nsmission.html

 

You might want to read this;

'04 Mountaineer/Explorer AWD T-Case Noise
<HR style="BACKGROUND-COLOR: #d1d1e1; COLOR: #d1d1e1" SIZE=1 itxtvisited="1"><!-- / icon and title --><!-- message --><!-- BEGIN TEMPLATE: ad_showthread_firstpost_start --><!-- END TEMPLATE: ad_showthread_firstpost_start -->My son just went through a situation with his Mountaineer. About 2 weeks ago he started hearing "snapping/Popping" noises in the drive train, usually when making a rt. turn. He was pretty sure it was an axle or the diff., I went for a ride with him and heard the noise and told him that it seemed to be more like under the middle of the truck and as he had an extended warrantee he should take it to Ford. He did and they said it was due to a loose bolt in the front end, they said they tightened it up and to come get it. He went to the shop and took it out for a short spin in the parking lot, it still had the noise. Took the service writer out and showed him that the noise was still there and back into the shop it went. They pulled the T-Case, split it and found that the pin holding one of the planet gears in the
planetary had slipped and was hitting the drive chain causing the "snapping/popping"noise. and had also knocked two of the outer links off the chain. A major disaster waiting to happen. After a bit of a hassle with the dealership and the warrantee co. it was decided that the warrantee co. would pay for a used T-Case with a 12mo/12,000 mile warrantee and my son would pay the $100 deductible, It turned out that the Tech broke 3 of the 4 bolts holding the X-member in and he also had to pay like another $140 in parts and labor to extract the bolt remains which included $60. for the 3 bolts that had never been removed before. Also the T-Case was nearly dry with no sign of outside damage or leaks and as the truck was serviced by that dealership we blamed the dealership for the lack of oil in the t/case.
The moral to all this is make sure you check your fluids and insist that those servicing your vehicle check the trans, t/case and dif(s) when you change oil and filter. We didn't fuss too much as the problem was taken care of without too much hassle and unexpected expense. Now we know to insist that ALL fluids be checked at each service even if it costs a couple extra bucks. The dealership we go to only charges $10.00 for an oil change and filter, using Ford parts and oil so it's a very good deal to take our cars there especially since we have 8 Ford products in our house.





<!-- / message --><!-- BEGIN TEMPLATE: ad_showthread_firstpost_sig --><!-- END TEMPLATE: ad_showthread_firstpost_sig -->

 

Gee I guess it was just a big waste of my time to bother posting the link to that very thread.

 

I didn't really find any large chunks of metal when I did the fluid change in the transfer case so it sounds like I may have the same condition as the Mountaineer had. I looked on-line and I can buy a rebuilt transfer case for $500 but I may be better off trying (from a $$) standpoint seeing if I can find one in the junk yard (like suggested). It seems like it would be cheaper to just replace the whole T-case then pay someone to break open the existing and diagnose or just drive with the fuse out until I get ready to trade it in on an Expedition EL

Thanks again for the responses.

Nathan

 

Did I miss something or was the Mounty's t-case run bone dry for an unspecified amount of time? Seems to me it was far from a random t-case failure but a failure based on vehicle neglect. In the case of the OP, the t-case had fluid in it, the fluid was changed and nothing seemed awry with that fluid. Can you say "shift motor"? Seems like it is not that hard to verify proper operation of the motor before condemning the t-case.

It is exceedingly rare for a properly maintained t-case to fail. If you want to run out and buy one and do the swap, be my guest. Or, you could do a little more diagnosis, and probably find out it can be fixed for $100.

I often wonder why people even ask for advice here. It must be my occasional fits of extreme boredom that prompt me to participate.

 

And here I thought it was your divine sense of grace.

 

The T-case was not bone dry but it was low on fluid with no sign of a leak. If there was neglect it was on the part of the Ford dealer that we take it to every 3,000 miles for oil and lube service. I agree that it is likely a rare occurance as the planet gear shaft came out of it's staked position and was hitting the drive chain breaking two of the links.
From the number of posts I have read there are quite a few AWD and 4WD trucks having a similar problem and until others identify their problem as the same as what we experienced I hold this info out only as a possibility. Not a diagnosis.
Have a nice day.

 

Thanks Big Greenie. Is there a way I can test to see if the shift motor is fully engaging or is this something I would need to take to a mechanic/4 wheel drive specialist to determine? Any insight appreciated.

Thanks

Nathan

 

Looks like I can buy a new shift motor for less than $100 and doesn't seem to difficult to replace. Just wondering if the motor isn't engaging all the way if that is an issue with the motor itself or with whatever the engagement mechanism is?

 

Take the existing motor off and see if you can manually move the mechanism and place the TC into 4WD. Along that same line, with the motor off yet still connected, move the shift selector switch (key on) and see if the motor moves.

 

I have replaced quite a few T-case chains. It is fairly common especially in ones where the 4wd has been used alot. Also when in low traction surfaces when the wheels break loose and the front engages it puts a shock load on the chain which further stretches and stresses it. So to say that it is unlikely the chain isnt a very well thought out comment.

 

That seems to be exactly what Big Greenie said! So why the contradiction?

 

Well, I can say I haven't really used my 4 wheel drive all that much but I know my truck tries to kick into the A4WD mode quite a bit. I definitely know this now since the TC is making the horrendous sound now when ever A4WD tries to engage. In fact my A4WD tries to engage even if my rear tires are not slipping. Examples are:

1. Cruising about 20 mph and I accelerate hard.
2. On interstate going up any kind of grade where the truck wants to downshift out of overdrive will make the TC engage as well. Basically any kind of load/torque does it.

This is probably an issue itself.