04' 4wd making noise | selector switch stuck possibly?

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Si I picked up my 04' EB yesterday. I notice when I start to take off from a complete stop, for about the first 20 ft it makes a rumble (driveshaft or axles) from underneath the chassis. I noticed the 4wd selector was on A4WD so I parked and put it in 2wd and the sound did not go away. I also noticed that no matter what position I turn the 4wd switch to, the backlight stays lit up on A4WD and doesn't move accordingly with the position of the switch.

Seems like it may be stuck in A4wd and maybe that is the sound I'm hearing from underneath on takeoffs...?
 

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ExpeditionAndy

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If the 2004 is like the 2005 you can shift from 2WD to A4WD or 4H on the fly. Here is the info from the 2005 manual:

Positions of the Control Trac system
The Control Trac system functions
in four modes:

• 2H (2WD HIGH) delivers power
to the rear wheels only. This is
appropriate for normal on-road
driving on dry pavement.

• A4WD (4X4 AUTO) provides
electronic control four-wheel
drive with power delivered to all
four wheels, as required, for
increased traction. This is appropriate for all on-road driving
conditions, such as dry road surfaces, wet pavement, snow or gravel.

• 4H (4X4 HIGH) provides mechanically locked four-wheel drive power
to front and rear wheels. The “4X4 HIGH” light will illuminate in the
instrument cluster when this position is selected. This position is not
recommended for use on dry pavement. This position is only intended
for severe winter or off-road conditions, such as deep snow, ice or
shallow sand.

• 4L (4X4 LOW) provides mechanically locked four-wheel drive when
extra power at reduced speeds is required. The “4X4 LOW” light will
illuminate in the instrument cluster when this position is selected.
This position is not recommended for use on dry pavement. Use this
position for off-road low-speed operation or when extra power is
required, such as climbing steep grades, going through deep sand or
pulling a boat out of the water.

Note: If your vehicle is equipped with AdvanceTrac with RSC, the
AdvanceTrac with RSC system will automatically turn off the stability
enhancement feature when you shift the Control Trac A4WD system into
4L (4X4 LOW). The brake traction enhancement feature will still be
enabled.

The AdvanceTrac with RSC stability enhancement system can be turned
off manually by pressing the AdvanceTrac with RSC button (refer to
AdvanceTrac with Roll Stability Control (RSC) Stability
Enhancement System in this chapter) while operating in 2H, A4WD or
4H while driving in deep sand, very deep snow or more strenuous
off-road maneuvers. This will disable the engine management feature,
allowing the vehicle to maintain full power and enhanced momentum
through the obstacle.

Shifting from 2H to A4WD or 4H
Move the control to the A4WD or
4H position at any forward speed up
to 55 mph (88 km/h). The “4X4”
light in the instrument cluster will
illuminate if 4H is selected.
Shifting from A4WD to 4H
Move the control from A4WD to 4H
at a stop or while driving at any
speed.

Shifting from 2H, A4WD or 4H to 4L
1. Bring the vehicle to a stop and
keep the brake pedal depressed.
2. Place the gearshift in N (Neutral).
3. Move the control to the 4L
position.
If any of the above shift conditions are not met, the message center will
display the appropriate information.
Note: Some noise may be heard as the system shifts or engages.
Shifting from 4L to 4H, A4WD or 2H
1. Bring the vehicle to a stop and
keep the brake pedal depressed.
2. Place the gearshift in N (Neutral).
3. Move the control to the 4H,
A4WD or 2H position.
If any of the above shift conditions
are not met, the message center will
display the appropriate information.
Note: Some noise may be heard as
the system shifts or engages.
 
Last edited:
B

bedrck46

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the following information was copied from the 2004 Ford Service Manual
hope it helps or gives you some ideas on where to look

The vehicle does not operate correctly in A4WD and 4WD HIGH modes
Central junction box (CJB) fuses:
11 (10A).
115 (30A).
20 (30A).
Mode select switch (MSS).
Transfer case shaft speed sensors.
Transfer case electric clutch.
4WD control module.
Powertrain control module (PCM).
IVD.
IWE solenoid.
Circuitry.
Go To Pinpoint Test B .

No communication with the 4WD control module
Central junction box (CJB) fuses:
115 (30A).
20 (30A).
4WD control module.
4WD control module connectors.
Circuitry.
Go To Pinpoint Test C .

The vehicle does not shift between 4X4AUTO/4WD HIGH and 4WD LOW modes correctly
Central junction box (CJB) fuses:
11 (10A).
115 (30A).
20 (30A).
Mode select switch (MSS).
Gearmotor encoder contact plate A, B, C, or D.
Gearmotor encoder assembly.
Circuitry.
4WD control module.
Transfer case internal mechanism.
Transfer case shift motor.
Digital TR sensor.
BPP switch.
IVD.
IWE solenoid.
4WABS control module.
Instrument cluster.
PCM.
Go To Pinpoint Test D .

The transfer case makes noise
Tire inflation pressure.
Tire and wheel size.
MAKE SURE that all tires and wheels are the same size and that the inflation pressures are correct.

Tire tread wear.
CHECK tire tread wear to see if there is more than 0.15 mm (0.06 in) difference in tread wear between front and rear. INTERCHANGE one front wheel and one rear wheel. ROAD TEST again.

Internal components.
OPERATE the vehicle in all transmission gears. If there is noise in the transmission in NEUTRAL, or in some gears and not in others, REMOVE and REPAIR the transmission. REFER to Section 307-01B . If there is noise in all gears, DISASSEMBLE the transfer case. REFER to Section 308-07B . CHECK the planetary gears, bearings, upper and lower drive sprockets and drive chain for damage. INSTALL new parts as necessary.

Fluid level.
FILL with automatic transmission fluid. REFER to Section 308-07B .
 

2005Expedition

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you just pick up ? where do you pick up from ? just bought it ? who ever had it before you must run the 4wd on high way speed ...
 
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bedrck46

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makes you wonder why the dealership sent it to auction.

See if there is anyway to contact the previous owner
 

2005Expedition

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It was purchased at the auction. It was a single owner ford dealer trade in.

I think the preview owner drive it in 4wd mode for quiet some time, then the problem came up, that why he trade it in,

or the person from the dealer was moving the car around at night and accident mistake turn the switch for the light, but he turn the 4wd mode, and drive it like that for a while...

anyway i think you will have to spend some major money on repair front diff ...

how much did you buy for 1500-2000 ? if 1500-2000 then the repair properly around 800-1200 dollar, at end that is how much that truck worth at the end.
 
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bedrck46

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I think the preview owner drive it in 4wd mode for quiet some time, then the problem came up, that why he trade it in,

or the person from the dealer was moving the car around at night and accident mistake turn the switch for the light, but he turn the 4wd mode, and drive it like that for a while...

are you sure or just guessing
 
OP
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I've got an ex-ford technician looking at it this week. I'll post back with what he comes up with. I'm not getting rid of the vehicle regardless of what's wrong with it.

I did notice that along with the indicator light on the 4wd switch not changing as knob is turned, the dashboard "4x4" never lights up either so I know at least there is a problem with the switch/fuse though I also suspect something wrong underneath.
 
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