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

Ford Explorer Fifth Generation (2011-2019)

Error Codes

2-4 hours

Time

medium

Difficulty

high

Severity

4 min read

632 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 troubleshoot and fix transfer case issues in Ford Explorer (2011-2019). Step-by-step guide with symptoms, diagnostic steps, and repair instructions.

Affected Component

Transmission

Estimated Time

2-4 hours

⚠️ Safety Warnings

Important safety information - read before proceeding

•Disconnect the battery before working on electrical components.
•Allow the vehicle to cool down before inspecting the transfer case to avoid burns from hot components.

Symptoms

•Inability to shift between 2WD and 4WD modes
•Grinding or clunking noises from the transfer case
•Illuminated warning lights on the dashboard (e.g., AWD or 4WD indicator)
•Fluid leaks under the vehicle
•Unusual vibrations while driving
•Slipping or loss of power to the wheels

Diagnostic Steps

1
Scan for error codes using an OBD-II scanner to identify any related trouble codes.
2
Inspect the transfer case fluid level and condition; check for contamination or signs of burning.
3
Visually inspect the transfer case for any physical damage or signs of leakage.
4
Check the transfer case control module connections for corrosion or looseness.
5
Test the transfer case motor operation by applying direct power to it and observing its response.
6
Examine the drive shafts and universal joints for wear or damage that could affect transfer case function.

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
•Fluid pump for transfer case fluid
•Fluid catch pan

Parts Required

•Transfer case fluid (Mercon LV)
•Transfer case actuator (if faulty)

Related Faults

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Diagnostic Steps

1
Scan for error codes using an OBD-II scanner to identify any related trouble codes.
2
Inspect the transfer case fluid level and condition; check for contamination or signs of burning.
3
Visually inspect the transfer case for any physical damage or signs of leakage.
4
Check the transfer case control module connections for corrosion or looseness.
5
Test the transfer case motor operation by applying direct power to it and observing its response.
6
Examine the drive shafts and universal joints for wear or damage that could affect transfer case function.

Solution

1. Preparation

Gather necessary tools and materials.
Disconnect the battery to avoid electrical shorts during the procedure.
Raise the vehicle securely with jack stands.

2. Fluid Change

Drain Old Fluid
- Locate the transfer case drain plug.
- Use a socket set to remove the plug and allow the old fluid to drain completely into a pan.
- Tools Required: Socket set, fluid catch pan.
Inspect for Metal Shavings
- Check the drained fluid for metal shavings or debris which could indicate internal damage.
Replace with New Fluid
- Reinstall the drain plug and torque it to the manufacturer’s specifications (typically around 30 ft-lbs).
- Fill the transfer case with the appropriate type of fluid (e.g., Mercon LV) until it reaches the fill plug level.
- Tools Required: Fluid pump for transfer case fluid, torque wrench.

3. Inspect and Repair Electrical Components

Check Wiring and Connectors
- Inspect the wiring harness and connectors to the transfer case control module for any signs of wear, corrosion, or loose connections.
- Repair or replace any damaged components.
Test Transfer Case Actuator
- If the actuator is faulty, replace it. Disconnect the actuator, then remove it using a socket set.
- Install the new actuator and reconnect the wiring.
- Tools Required: Socket set, wiring repair kit if needed.

4. Reassembly and Testing

Reinstall Components
- Reinstall any panels or covers that were removed during the inspection.
- Reconnect the battery.
Test Drive
- Conduct a test drive to confirm that the transfer case engages and disengages properly and that no abnormal noises are present.