Transfer Case 4405 PDF

1995 Ford Truck Explorer 2WD V6-245 4.0L Copyright 2011, ALLDATA 10.
50PE Page 1
Transfer Case: All Technical Service Bulletins
Transfer Case - Shudder/Binding Diagnostics
Article No.
97-3-14
02/03/97
TRANSFER CASE - BINDING OR SHUDDER -
DIAGNOSTICS - VEHICLES WITH 4.0L ENGINE -
SERVICE TIP
LIGHT TRUCK:
1995-97 EXPLORER
ISSUE:
The diagnostic procedure for binding or shudder from transfer case in slow, tight turns while in 4 Auto mode may be inaccurate for some vehicles.
ACTION:
Diagnose transfer case binding or shudder concerns using the following Diagnostic Procedure.
DIAGNOSTIC PROCEDURE
1997 EXPLORER
1. Test drive the vehicle in 4 Auto, 4 High and 4 Low. Evaluate the vehicle in each of these modes. The vehicle should bind in turns in both 4 High
and 4 Low, but not in 4 Auto. The 4 High mode is intended for severe winter weather or off-road driving only. It is not intended for use on dry
or merely wet pavement.
2. Verify the instrument panel has the proper 4X4 selection label (Figure 1). Proceed to 1995-97 Explorer heading, Step 1.
1995-97 EXPLORER
NOTE:
4 AUTO IS THE FAR LEFT SWITCH POSITION ON 1997 MODELS AND IS THE MIDDLE POSITION ON 1996 MODELS.
1. If during test driving, the vehicle shudders or binds in 4 Auto during slow forward or reverse parking lot maneuvers, proceed to Step 2.
2. Connect the New Generation Star (NGS) Tester to the Data Link Connector (DLC) underneath the steering wheel. Monitor for any Diagnostic
Trouble Codes (DTCs) set by the transfer case that could indicate incorrect speed sensor function. Codes could include, but are not limited to:
^ P1836 - Front propshaft sensor circuit failure
^ P1837 - Rear propshaft sensor circuit failure
^ P1874 - Hall effect sensor power short circuit to battery
^ P1875 - Hall effect sensor power circuit failure
NOTE:
ADDITIONAL CODES COULD BE SET AS WELL. PLEASE REFER TO THE APPROPRIATE YEAR EXPLORER SERVICE MANUAL FOR
COMPLETE LISTING AND EXPLANATION.
1995 Ford Truck Explorer 2WD V6-245 4.0L Copyright 2011, ALLDATA 10.50PE Page 2
3. If any of the DTCs in the above Step 2 are set, remove the corresponding speed sensor and replace accordingly. Drive the vehicle to verify if the
shudder/binding has been eliminated. Send replaced speed sensor to the Ford Warranty Parts Return Center, Canton, MI.
4. Using NGS Tester, monitor the Parameter Identification Display (PID) on the transfer case clutch duty cycle. If the 4 Auto mode reads
something higher than one (1), verify speed sensors have not set any Generic Electronic Module (GEM) DTCs and follow the speed sensor
diagnostic procedure in the above Step 2. Verify the following while checking PID:
Mode Duty Cycle Indicator
4 Auto 0 or 1
4 High 13
4 Low 38 at 5 MPH
5. If the speed sensor circuits are functional, inspect for water contamination in the transfer case oil:
a. Drain the old transfer case fluid and replace with 1.42 Litres (48 oz.) of Motorcraft MERCON(R) Multi-Purpose Automatic Transmission
Fluid (ATF) (XT-2-QDX), or equivalent meeting the MERCON(R) specification.
b. Idle the vehicle in drive for 5 minutes on the hoist in 4X2 mode (1995-96 Explorers) or with the transfer case shift motor disconnected
(1997 Explorer). Disconnecting the motor will simulate 4X2 mode and will cause differential speeds across the transfer case clutch plates.
This will ensure any water caught between the clutch plates gets purged.
c. Drain the fluid and refill with 1.42 Litres (48 oz.) of MERCON(R) ATF again.
d. Evaluate for shudder or binding by driving the vehicle in the 4 Auto mode in slow, tight turns.
NOTE:
WATER ON THE TRANSFER CASE CLUTCH PLATES CAN REQUIRE MULTIPLE DRAIN AND REFILLS TO FULLY PURGE OF
CONTAMINANTS.
e. If binding or shudder still exists and contamination was severe enough to have caused the original fluid to turn milky, repeat the
procedure of cycling vehicle, draining and refilling transfer case, and evaluate again.
6. If draining and refilling the transfer case solved the concern, a revised Vent Tube should be installed to prevent future contamination. Refer to
TSB 97-1-16.
7. If the above diagnostic actions do not resolve the problem, inspect the six-digit number on the transfer case aluminum identification (ID) tag. If
the serial number is anywhere between 609347 and 615997 or between the numbers 100329 and 106251, then call the Borg-Warner Hotline at
(317) 286-6234 for assistance on this unit. The ID tag is located on the rear of the transfer case (Figure 2).
8. If the procedure in this TSB article does not resolve the binding or shudder condition, please contact Borg-Warner Automotive Hotline (317)
286-6234.
OTHER APPLICABLE ARTICLES: 97-1-16
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 508000, 703000

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1995 Ford Truck Explorer 2WD V6-245 4.0L Copyright 2011, ALLDATA 10.

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