my Ford Explorer's transfer case is making noise what should I check

Ford Explorer Fifth Generation (2011-2019)

Error Codes

2-4 hours

Time

medium

Difficulty

medium

Severity

3 min read

506 words

Problem Statement

Learn how to diagnose and fix transfer case noise in Ford Explorer. 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 systems.
•Allow the engine to cool before accessing the transfer case.

Symptoms

•Unusual grinding or whining noise from the transfer case
•Difficulty shifting between 2WD and 4WD modes
•Vibration felt through the vehicle during acceleration
•Fluid leakage around the transfer case
•Warning light illuminated on the dashboard (if applicable)

Diagnostic Steps

1
Inspect the transfer case fluid level and condition.
2
Check for any visible leaks or damage around the transfer case.
3
Listen for noise while engaging different drive modes (2WD, 4WD).
4
Scan for any error codes using an OBD-II scanner.
5
Inspect the driveshaft and universal joints for wear or damage.
6
Check the transfer case mounts for any signs of wear or failure.

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

•Socket set
•Torque wrench
•Fluid catch pan
•OBD-II scanner
•Safety glasses

Parts Required

•Transfer case fluid
•Any worn or damaged internal components (gears, bearings, chain)

Related Faults

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Diagnostic Steps

1
Inspect the transfer case fluid level and condition.
2
Check for any visible leaks or damage around the transfer case.
3
Listen for noise while engaging different drive modes (2WD, 4WD).
4
Scan for any error codes using an OBD-II scanner.
5
Inspect the driveshaft and universal joints for wear or damage.
6
Check the transfer case mounts for any signs of wear or failure.

Solution

1. Preparation

Gather tools: socket set, torque wrench, fluid catch pan, OBD-II scanner, and safety glasses.
Disconnect the battery to prevent electrical shocks.
Allow the vehicle to cool down if recently driven.

2. Check and Replace Transfer Case Fluid

Sub-step 1: Locate the transfer case drain and fill plugs.
Sub-step 2: Place a fluid catch pan under the drain plug and remove it to drain old fluid.
Sub-step 3: Inspect the removed fluid for metal shavings or debris indicating internal wear.
Sub-step 4: Reinstall the drain plug and torque it to manufacturer specifications.
Sub-step 5: Use a funnel to fill the transfer case with the appropriate type and amount of fluid as specified in the owner’s manual.

3. Inspect Internal Components

Sub-step 1: If noise persists after fluid replacement, remove the transfer case from the vehicle.
Sub-step 2: Disassemble the transfer case carefully and inspect gears, bearings, and chain for wear or damage.
Sub-step 3: Replace any damaged components with OEM parts.
Sub-step 4: Reassemble the transfer case and torque all fasteners to specifications.

4. Reinstall and Test

Sub-step 1: Reinstall the transfer case onto the vehicle.
Sub-step 2: Reconnect the battery.
Sub-step 3: Conduct a test drive to ensure the noise has been eliminated and the transfer case operates smoothly.