how to fix Ford Explorer Fifth Generation (2011-2019) issues with the transfer case

Ford Explorer Fifth Generation (2011-2019)

Error Codes

3-6 hours

Time

medium

Difficulty

high

Severity

3 min read

594 words

⚠️ Safety Warning

This issue requires immediate attention. If you are not experienced with automotive repairs, consult a professional mechanic. Working on critical systems can be dangerous.

Problem Statement

Learn how to diagnose and fix transfer case issues in Ford Explorer Fifth Generation (2011-2019). Step-by-step guide with symptoms and repair instructions.

Affected Component

Transmission

Estimated Time

3-6 hours

⚠️ Safety Warnings

Important safety information - read before proceeding

•Disconnect battery before working on electrical systems
•Allow the vehicle to cool before working on the transfer case to avoid burns

Symptoms

•Unusual grinding or clunking noises when shifting into four-wheel drive
•Warning lights illuminated on the dashboard, such as 'AWD Fault'
•Difficulty in engaging or disengaging four-wheel drive
•Slipping or jerking during acceleration
•Fluid leaks around the transfer case
•Increased fuel consumption

Diagnostic Steps

1
Scan for error codes using OBD-II scanner
2
Inspect the transfer case and surrounding areas for signs of fluid leaks or physical damage
3
Verify the transfer case fluid level and condition
4
Engage the four-wheel drive system and check if the actuator is functioning properly
5
Examine the wiring and connectors related to the transfer case for corrosion or damage
6
Physically inspect the transfer case components for wear

Solution

💡 Expert Tip

For complex repairs like this, consider taking photos at each step. This helps if you need to reverse a step or consult with a mechanic. Also, keep all removed parts organized - you may need to reference them during reassembly.

Verification

After completing the repair, verify that the issue has been resolved:

✓Test the affected component to ensure it functions correctly
✓Check for any error codes or warning lights
✓Monitor the vehicle for a few days to ensure the issue does not recur

Prevention Tips

To prevent this issue from occurring again:

•Follow the manufacturer's recommended maintenance schedule
•Address warning signs early before they develop into major issues
•Use quality parts and fluids recommended for your vehicle
•Keep detailed records of all repairs and maintenance

Tools & Equipment Required

•OBD-II scanner
•Socket set
•Torque wrench
•Drain pan
•Screwdrivers
•Pliers

Parts Required

•Transfer case fluid (Ford Motorcraft recommended)
•Actuator (if faulty)
•Seals and gaskets for the transfer case

Related Faults

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Symptoms

•Unusual grinding or clunking noises when shifting into four-wheel drive

•Warning lights illuminated on the dashboard, such as 'AWD Fault'

•Difficulty in engaging or disengaging four-wheel drive

•Slipping or jerking during acceleration

•Fluid leaks around the transfer case

•Increased fuel consumption

Diagnostic Steps

1
Scan for error codes using OBD-II scanner
2
Inspect the transfer case and surrounding areas for signs of fluid leaks or physical damage
3
Verify the transfer case fluid level and condition
4
Engage the four-wheel drive system and check if the actuator is functioning properly
5
Examine the wiring and connectors related to the transfer case for corrosion or damage
6
Physically inspect the transfer case components for wear

Solution

1. Preparation

Gather Tools and Parts: Obtain necessary tools and parts for the repair.
Safety Precautions: Disconnect the battery to prevent accidental electrical shorts.

2. Drain and Replace Fluid

Drain Fluid: Place a drain pan under the transfer case, remove the drain plug, and allow all fluid to drain completely.
Replace Fluid: Reinstall the drain plug and refill the transfer case with the manufacturer-recommended fluid type (typically Ford Motorcraft Transfer Case Fluid).

3. Repair or Replace Components

Inspect and Replace Actuator: If the actuator is faulty, disconnect it, remove any retaining screws, and replace it with a new unit.
Replace Seals and Gaskets: If leaks are present, remove the affected components, clean surfaces, and replace any worn seals or gaskets.
Inspect Internal Components: For grinding noises, disassemble the transfer case, inspect gears and chains for wear, and replace any damaged parts.

4. Reassemble and Test

Reassemble Transfer Case: After all necessary repairs, reassemble the transfer case ensuring all components are secured.
Reconnect Battery: Reconnect the battery and ensure all electrical connections are secure.
Test Drive: Conduct a test drive to ensure that the transfer case functions properly and that no unusual noises or symptoms persist.