Vehicle will only drive when it is in 4 wd low range

MFGT20

MEMBER
1995 FORD EXPLORER
4.0L
V6
4WD
MANUAL
198,000 MILES

It makes all kinds of noise when it's 2wd or 4wd high. We checked the switch motor and it's good. We removed it and manually turned it in to 2wd, but it goes for a short distance then kicks out. What do it need to replace or fix so I have a SUV running again without having to run 4 low?

Wednesday, June 1st, 2022 AT 9:03 PM

1 Reply

KASEKENNY

MECHANIC
18,907 POSTS

Where is the noise coming from in 2WD or High? If this is coming from the transfer case, then more than likely the input shaft or drive chain is slipping.

I would suggest removing the front drive shaft and see if the noise goes away.

https://www.2carpros.com/articles/how-to-remove-a-drive-shaft

Basically, if this is happening in 2WD as well then, we may have a different issue. However, the input shaft is just a pass through in 2WD so it is still turning.

In Low, the power flow is different, so I suspect we have an internal issue.

I am attaching the basic testing as well that we need to run through in order to prove this out.

Let me know if you have questions but it sounds like we may need to replace the transfer case.

Images (Click to make bigger)