Ford Transmission :: 1995 F250 - Transfer Case Grind - Only In Reverse?
Nov 29, 2008
I have a '95 F-250 7.3 auto 4X4. The transfer case linkage has been floppy and prone to coming apart since I've had it, but that's been fine for me. I let my brother use the truck last weekend, and now it does the following: When you put the transmission in reverse, or when the truck overruns the engine (compression braking) it grinds badly like the transfer case isn't quite engaged. Only does it in 2 or 4 Hi, and everything's normal otherwise.
Could the transfer case have jumped out of gear while he was driving it, and he didn't know to either push it into gear or pull it into neutral before it did damage? I really don't want to pull a transfer case in my driveway in December in New England, but give it to me straight.
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Made a short run to get lumber yesterday and when I got home the truck smelled hot I checked it out and found a transmission oil leak at the rear of the transmission in front of the transfer case. can not really see what is leaking only has 22,000 miles. What may have happen. 2011 F250 4x4 6.7....
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just bought the truck first time out hit some snow and it was not engaging low or high range, but I noticed that when I was backing up it was engaged again works in high and low range, i had to reverse about a mile up the road but it worked ? 99 4.2 standard with manual shift transfer case....
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About 9 months ago heard a strange noise when shifted into 4 wd , sounded like driving over those grooves on the side of the highway to keep people awake.
Had to pull over to stop , as it would not go back into 2wd with the noise still going.
Then it stopped , after shutting truck off and restarting.
Then earlier this year after trying to do it again in 4wd had bad clunking noise and was hard to get back in 2wd , I can here the shift motor engaging and the dash reads in 4wd, seems its not engaging fully in 4wd and not going back to 2wd, its a very bad clunking noise, shakes the whole truck.
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I have a BW 1345 transfer case. Does it have the shift in the fly capability? And, if so, what precautions should be taken if shifting on the fly?
Second, where can I get a "plate" or label that shows the shift pattern? I know the shift pattern, I just want to post it in my vehicle in case anyone else ever drives it and needs to use the 4 wheel drive.
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I found that my transmission was low on oil but couldn't find a leak. What I did find is that the seal in the transfer case was letting trans fluid transfer into it and then it would leak out the out put seal. I purchased the new seal and gasket and repaired it myself in about 3 hours. I removed the rear drive shaft and removed the front drive shaft from the transfer case alone or you can take it out completely if you want.
Drained transfer case unplugged wiring and one vacuum line. Unbloted from trans and removed using trans jack. The bolts are not the easiest to get to. i used a 3/8 ratchet to break them loose then used a stubby 3/8 to get them out because they are around 2 inches long. Once down I had to jack up the truck to get it out from under it. I removed the old seal and installed new one cleaned everything up and installed with a new gasket.
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We have a 2000 F250 7.3L Diesel. A few years ago we switched out the auto hubs for manual Warn hubs. We've had no problems with 4x4 since that time, until now!! The 4x4 Hi light is on and the transfer case is engaged. Since the hubs are manual we have them unlocked, however we can't get the 4x4 to disengage. At one point, tried changing to low and it hesitated but finally went in to 4 Lo, then we had a hard time getting it out of 4Lo and back to 4 Hi. Here's what we've tried--checked fuses, checked and replaced relays, checked wiring connection at the transfer case. Husband used volt meter to test power at transfer case wiring connector--showed 0.5 volt of power with the key on. No change in reading. Checked power at relay--about 14.5 volts there. Took truck to repair shop but their computer could not communicate with the GEM.
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My 2000 explorer has picked up a clutch chatter when taking off with the wheels turned. It is AWD, and has an 8.8" LS rear end with and 173k on the clock. Is there any good way to tell where the chatter is coming from? I know how to check the TC clutch, but it requires dropping one of the driveshafts.
I may try changing the rear diff lube, as I am sure it's never been done. They say "lube for life" but no fluid can last forever, I would think.
Also, on that note... a couple years ago I had a pinion seal leaking and the shop said it was 2 quarts low when they fixed it and said "rear diff damage has probably already occurred" on the ticket. While that is possible i suppose, would think i would have major problems right away as the diff only holds 2.5 qts (IIRC). Least wise, that was probably 50k miles ago when I had it fixed.
More than likely, the mechanic was an idiot and it was only .5 qts low, as i'm 99% sure that they left the pinion nut loose when he did the job. (had a terrible vibration that mysteriously went away when i brought it back for them to find out what is going on .. they said they didn't do anything, but it was fixed when i got it back ... they don't get my business anymore)
Anyway ... would i be able to feel that clutch chatter with one rear wheel in the air and the trans in neutral? Assuming the worst case scenario, and the TC clutch is going out, how big of a deal is it? Can i get another 20K-30K out of it before it gives up the ghost?
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I had my truck at the shop today and it was determined that the transfer case front driveshaft seal is leaking and the gasket between the transmission and transfer case has also failed. The shop wants a reasonable amount to fix it but they need the truck for 2-3 days. It doesn't appear to be that difficult of a job to remove the transfer case. Am I missing something? Dropping off the truck and leaving it for a few days is the difficult portion......if they could do it in a day I'd just pay them and be done with it. So my thought was to pull it and just drop it off so they can replace the seals and fix any other issues.
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2001 F250, 7.3L ... After much diagnosis, I've found that the 4 positive feeds to the transfer case relay base have no power to them. The fuse that feeds them (#17 CJB) is fine and when I jump from the fuse hot side directly to the transfer case motor contacts on the relay base, it shifts fine. As far as I can tell, there is only one wire leading from that fuse so there must be a junction block somewhere that splits it into the 4 wires that feed the relay block. I've looked underneath and found nothing. How the 1 wire gets split into 4? On diagrams this junction point is labeled, but I don't know where to find that.
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I just changed transfer case fluid on my father's F-350 for the first time in 13 years. (over 230k). Removed fill plug first and fluid gushed out of the fill hole unexpectedly. Did not have catch pan ready, so made a mess. I thought it was just over filled form the factory, but too much was coming out to be simple overfill. Almost 2 qt came out of the fill plug.
Did some google search and found many Ford trucks have failed transmission output shaft seal and transmission fluid leaks out to transfer case, causing transfer case to overfill. I am yet to check transmission fluid level, but considering how much came out of it that probably is the case.
Now, how bad of the problem this really is? Will overfilled transfer case cause some serious problem? 4x4 is rarely used (once or twice a year in winter) on this truck and from what I understand transfer case doesn't really do anything in 2WD other than just passing output from transmission through.
There are no fluid leaking outside and repairing the seal would be a too much of work for me.
Also changed rear differential fluid for the first time and I was surprised how clean the fluid was. There were thin layer of black sticky residue (sludge?) covering everything, but the fluid itself looked clean and no visible metal shavings. I guess that is why Ford said it does not require change under normal condition.
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I recently bought a 1995 Bronco. The rear axle makes a pretty awful noise. I put it on jackstands and ran it while I laid under the truck and it's coming right from the differential. It makes a constant howling noise and it felt like there was something banging against the inside of the case.
I removed the inspection cover and drained all the fluid out. It looked like chocolate milk, but the gears themselves all look fine. I didn't find any broken teeth, metal shavings, pieces of bearings, etc. in the case. It looks like a perfectly normal differential.
The truck has 166,000 miles on it and doesn't appear to be abused at all.
Here's a video I shot of the noise. You can't really hear the howling noise but the knocking sound is pretty audible. The frequency changes with the wheel speed. The sound is definitely coming from the differential.
Bronco axle - YouTube ....
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Looking at another Ex but the owner says the transfer case does not engage. Says it can be locked into 4X4 by crawling under it and engaging it manually by removing a motor [Servo motor ?] Does this mean I would need a new transfer case or just the servo motor ? I know mine did the same thing last winter. It would go into 4X4 and then pop out.
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I just replaced the transfer case BW 4405. And I noticed that the 2 sensors (front drive shaft and rear drive shaft) are bad. What is the name of these two sensors? I'm looking for a brand new ones...
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Where/how to check the ATF in the transfer case? I found the lower drain bolt,but I don't see anything up higher that looks like a fill hole.
'91 Aerostar 4.0L AWD
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2003 ex 6.0 limited....300000 miles ...Automatic.Merry Christmas to all.My Transfer case will not shift into 4wd . Dash light for 4wd high and low works .I get no power to transfer case 2pin connector when key turned on.Also fuses 19,27,31,33,34,45,111 are all good when checked with meter.I also swapped 2 relays in engine compartment and no change.4 WD Switch on dash has power on Green/red wire I think it is for dash light and not for operation.
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Swapped out my transfer case since mine was detonated and now my tranny is running hotter? Drove in town for about 10-15 minutes and noticed my temps climbing and once it got to 180 it felt like it was slipping when moving from a full stop. i went home and parked it. Checked my fluid level and it looked a little low so topped it off while running and went through gears to make sure it was good. Drove again and it still went up to 180 in 10-15 minutes in town driving. Before we swapped the transfer case it was driving fine and went on a road trip 6 hour drive and felt fine. I bought the excursion and it supposedly had a new tranny in it.
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So long story short I have a 92 Aerostar AWD which I'm pretty sure had the transfer case recall done (97V204000 1992 FORD AEROSTAR Recalls) it has the aluminum driveshaft but a couple of years ago the transfer case cracked and I replaced it with a "New OEM" transfer case off eBay. Fast forward to the present and my van has a strong vibration at 60+ my transmission guy says it all looks good so the vibration has to be from one of the driveshafts. My thought is that I may have got a transfer case without the recall done on it and its warped my driveshaft. I don't really know thats possible or what I could do about it if that was the case.
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I bought a new to me 03 explorer 4.6 tow package XLT 136000mi. Rebuilt aamco trans with 10k on it. Been checking it over before i put it on the road.. No 4x4 but the button lites work and i got into low range once. (Had a hell of a time getting back to high but eventually it did). Question is if there is 12v at the brown wire on the TC the case should be fully locked? I figure when i check it if there is not 12v at the brown wire in 4x4 high i could apply 12v directly with a jumper wire to see if the case locks to 4x4. Am I correct?
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The dang thing leaks from the fill plug, I been reading about using liquid teflon on it.
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I had sold my Explorers but just picked up a 2000 Excursion V10 plow truck. It has been hacked and slashed I find cut wires under the dash and hood. I have tried everything to get the 4x4 to engage and no luck. It is used just for my driveway no road driving...
So question is: Can I engage the 4x4 at the transfer case so it will go, and stay in 4 wheel drive. If so do I take the shift motor off or does that big bolt by the motor do anything.
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