2003 Expedition 4WD Transfer Case trouble

[Basimos]

Hi Guys,
This is my first post in here. Thanks for a lot of useful information posted on the forum but I guess I have a new topic that I need your help with. I have a 2003 Expedition XLT 4WD with almost 198K Mile on It and continue to performs very well with my off-road trips in Dubai Desert sand dunes on 4H settings "almost every weekend" I only use 4L when it's very necessary in technical areas with soft sands or high climbs.

I have replaced the front differential box a week ago "used one" and I started to feel that the car is very heavy like towing a truck while driving 2H on asphalt roads. It feels like I am on 4H at all times, then I started to hear like grrrrr noise between gear shifts on highways and I am sure it's not the gear coz I don't feel it slips or something it's just too heavy to drive.

The mechanic told me that it is the transfer case that would cause this trouble but I thought I would check in here first. I truly appreciate your replies.
Cheers.

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[Basimos]

I forgot to say that I have a 3" lift kit with 285/70 R17 cooper A/T3 tires on it.

 

[John Stephan]

Check fluid level in the transfer case by pulling the fill plug. If it's over full, you have an issue with the rear seal on the trans. You could also pull the drain plug on the transfer case and get a fluid sample. Check for sparkly bits.

Also have someone shift from 2H, 4H and 4L while you watch and listen for the gear selector on the back of the case. The actuator can fail as can the internals. Assuming it's an electronic selector.

Sent from my SM-G950U using Tapatalk

 

[Basimos]

Check fluid level in the transfer case by pulling the fill plug. If it's over full, you have an issue with the rear seal on the trans. You could also pull the drain plug on the transfer case and get a fluid sample. Check for sparkly bits.

Also have someone shift from 2H, 4H and 4L while you watch and listen for the gear selector on the back of the case. The actuator can fail as can the internals. Assuming it's an electronic selector.

Sent from my SM-G950U using Tapatalk

Thank you for this procedure. I will check the same and get back to you with results.

 

[01exp4x4]

I have a 2003 4x4 with 5.3 and 101,000 miles.
I have been using 4x4 high and Auto 4x4 a lot lately, winter here with snow.


I have heard and felt a Strange grrrr noise that has developed recently.

It is random. It does not always happen.

Sometimes a clunk sound, or abrupt feeling of engagement or disengagement, ...maybe.

I was considering a rebuilt transfer case.

The automatic engagement or "auto 4x4" transfer case has clutches in it.

Was also thinking that the wheel hub is operated by vacuum actuated hubs.

Please update what you come up with.

Jimmy.

 

[Basimos]

Sorry for my late reply. Well, I brought the car to the same mechanic where he found the oil level a bit low but realy bad, the 4x4 switch was slow and not respnding at some times. I decided to tak the chance of replacing it where I was lucky enough to find a clean set at a local used parts dealer that sosts me about 150$ plus 100$ labor

The use of 4X4 switch is much better now with quick response and smooth drive.

Thanks for your support.
Cheers

 

[Basimos]

I have a 2003 4x4 with 5.3 and 101,000 miles.
I have been using 4x4 high and Auto 4x4 a lot lately, winter here with snow.


I have heard and felt a Strange grrrr noise that has developed recently.

It is random. It does not always happen.

Sometimes a clunk sound, or abrupt feeling of engagement or disengagement, ...maybe.

I was considering a rebuilt transfer case.

The automatic engagement or "auto 4x4" transfer case has clutches in it.

Was also thinking that the wheel hub is operated by vacuum actuated hubs.

Please update what you come up with.

Jimmy.

Dear Jimmy,

Based on my practice, the transfer case was to blame for all the troubles on my car. I have almost 195K miles on it and still going off-road. Driving on sand dunes is much harder than snow especially when it comes to high climbs.

You are probably having a similar situation due to the use of 4x4.
Again, check oil level and quality before you go on with the replacement.

Good luck
Basimos