how to fix Ford Explorer Fifth Generation (2011-2019) transfer case problems

Ford Explorer Fifth Generation (2011-2019)

Error Codes

3-5 hours

Time

medium

Difficulty

high

Severity

4 min read

666 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 problems in Ford Explorer Fifth Generation (2011-2019). Step-by-step guide with symptoms and repair instructions.

Affected Component

Transmission

Estimated Time

3-5 hours

⚠️ Safety Warnings

Important safety information - read before proceeding

•Disconnect the battery to prevent electrical shorts

Symptoms

•Difficulty engaging four-wheel drive
•Unusual noises (grinding or clunking) from the transfer case
•Transmission slipping or harsh shifting
•Warning lights illuminated on the dashboard (e.g., 4WD indicator)
•Fluid leaks under the vehicle
•Poor vehicle traction in slippery conditions

Diagnostic Steps

1
Scan the vehicle's onboard computer using an OBD-II scanner to check for any error codes.
2
Inspect the transfer case fluid level and condition; look for signs of contamination or low levels.
3
Examine the transfer case for any visible leaks or damage to the seals.
4
Test the operation of the four-wheel drive system by engaging it in different modes.
5
Check the wiring and connectors associated with the transfer case control module for corrosion or damage.
6
Inspect the transfer case shift motor for proper function and any signs of 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
•Multimeter
•Seal puller
•Gasket scraper
•Drain pan
•Funnel

Parts Required

•Transfer case fluid
•New seals
•Transfer case shift motor (if replacement is necessary)

Related Faults

Share this solution

Comments

No comments yet

Be the first to share your thoughts

Back to Generation

Diagnostic Steps

1
Scan the vehicle's onboard computer using an OBD-II scanner to check for any error codes.
2
Inspect the transfer case fluid level and condition; look for signs of contamination or low levels.
3
Examine the transfer case for any visible leaks or damage to the seals.
4
Test the operation of the four-wheel drive system by engaging it in different modes.
5
Check the wiring and connectors associated with the transfer case control module for corrosion or damage.
6
Inspect the transfer case shift motor for proper function and any signs of wear.

Solution

1. Preparation

Gather tools and parts needed for the repair.
Ensure the vehicle is parked on a level surface and securely lift it using jack stands.
Disconnect the battery to prevent electrical shorts.

2. Drain and Replace Transfer Case Fluid

Tools Required: Socket set, drain pan, funnel.
Sub-steps:
1. Place a drain pan underneath the transfer case.
2. Remove the drain plug using a socket wrench and allow the old fluid to completely drain.
3. Inspect the drain fluid for metal shavings or excessive contamination.
4. Replace the drain plug and torque it to the manufacturer’s specifications.

3. Inspect and Replace Transfer Case Seals

Tools Required: Socket set, seal puller, gasket scraper.
Sub-steps:
1. Remove the transfer case from the vehicle if necessary (follow manufacturer guidelines).
2. Use a seal puller to extract old seals from the transfer case.
3. Clean the seal mounting surfaces with a gasket scraper.
4. Install new seals, ensuring they are seated properly.

4. Repair or Replace Transfer Case Shift Motor

Tools Required: Socket set, multimeter, wiring harness repair kit (if needed).
Sub-steps:
1. Disconnect the wiring harness from the shift motor.
2. Use a multimeter to test for power and ground at the motor connector.
3. If the motor is defective, remove it from the transfer case.
4. Install a new shift motor and reconnect the wiring harness.

5. Refill Transfer Case with New Fluid

Tools Required: Funnel.
Sub-steps:
1. Fill the transfer case with the appropriate type of fluid as specified by the manufacturer.
2. Use a funnel to avoid spillage and fill until the fluid begins to seep out of the fill hole.
3. Replace and secure the fill plug.

6. Reconnect Battery and Test Drive

Reconnect the battery and start the vehicle.
Test the four-wheel drive system in various modes to ensure proper operation.