Question about 1996 Ford Explorer

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96 explorer disengages 4wh low but does not engage 2wheel

I bought a 96 ford explorer about 8 days ago , it ran good i drove it for about 40 miles it was running good on 2wheels but the transmissions slipped once when I was on high speed and went to a lower speed , I put the car on N then On D and the transmission went back working fine , I drove it for 2 days and it was running good , then on the 4th day I wanted to try the 4 wheel drive low , I pressed the brakes all the way put the car on N moved the switch to 4wheel low , I heard the mechanism changing into 4w low and drove on 4 wheel low for about 10 minutes and it drove forward and reverse well , it made a sound that it need lubrications on the 4w low mode , I stopped pressed the brakes all the way put it on N and put the switch on 2wheel , it shifted out of 4wheel but it did not engage 2 wheel drive , I was really close from home , I put back to 4wheel low and drove it to my place , took it to my garage , I searched online for the problem and I did some of what I read on the ford forums to engage the 2 wheel drive again . 1 I unplugged the battery for 30 minutes to reset the GEM , then I turned on the car pressed the brakes put it on N and switched it to 2wheel , it did not engage and car stayed as if in neutral , I engaged the 4wheel low and heard it shifting to 4wheel low , I pressed the brakes all the way put it on N then moved the switch to 2wheel , it disengaged the 4w low but did not shift to 2wheel it shifted as if it is in neutral . 2 i turned of the car, jacked it up , put it in N made one my friend sit in it switched it to 4wheel low , then told him to put it in N , switch to 2wheel , I hammered the transfer case switch with a rubber mallet , still the car disengaged the 4wheel low , but when shift to 2wheel it is like in neutral . 3 I got the manual checked the vacuum solenoids under the hood on the left front side C1007 and C1006 and they both work fine , I also checked the C1004 disconnect switch and it works fine. 4 I tried putting the car on 4wheel low , drove it back words for about 60 meter , pressed brakes then N then switch to 2wheel and still does not shift , do I change the shift transfer case motor , it disengages the 4wheel but the 2 wheel does not engage and act like Neutral When the vehicle switch is on 2 wheel, wither it is on D or R it is like neutral when I tried to put it on Park it made like a crrrrrrrrrrrrr sound so I did not try to do that again , it does not go on park when switch is on 2wheel and when D Or R it feels the Same as on neutral , it tried it on the ramp it slips back and forward what other tests should I do to diagnose my problem here

Posted by Mohamed Helmy on

  • Mohamed Helmy
    Mohamed Helmy Mar 31, 2014

    well it has only a switch that goes from 4wheel low , to auto wheel , to 2wheel drive , it has automatic transmission



1 Answer

Dan Jacobs

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Does it shift to 4wd high range ? If so then shift to 2wd . What is going on here is the transfer case motor is stopping due to the motor position sensor has gone bad which means that you replace the transfer case motor assembly. But if you wish to make it a 2wd for awhile then remove motor and manually turn shaft . This can be done by raising and supporting rear axle truck in park remove motor turn shaft slowly with pliers and rotating the play in drive shaft. There are stamped markings on back of case showing gear positions..

Posted on Mar 31, 2014

  • 1 more comment 
  • Dan Jacobs
    Dan Jacobs Mar 31, 2014

    This has a Borg Warner Transfer case and a motor on the back side of facing the rear with 3 mounting bolts through motor and 1 near the bottom of motor case remove it and watch it operate . The grinding noise you here it the output shaft from the transmission is turning while your transfer case is in neutral.

  • Mohamed Helmy
    Mohamed Helmy Apr 02, 2014

    i jacked the car up on all 4 , took off the transfer shift motor , kept it plugged in turned in the switches it works fine , i looked in the place it was mounted it said High to N to Low , i used pillars it manually from low to High , then i started the car put on 2w , pressed brakes put it drive but it doesn\'t drive in 2 wheel , non of the wheel spin , on 2w or high , that would be the transfer case assembly or the transmission its self ???

  • Dan Jacobs
    Dan Jacobs Apr 04, 2014

    the problem would be internal in transfer case because when putting into park the park pawl is ratcheting that means the output shaft of trans is turning . with tires off the ground start and put trans in gear step on gas slightly watch to see if tach moves or listen for changes that means the trans is shifting. the problem is the transfer case oil pump has gone out and the output shaft is above the fill hole and has not been getting oil to keep it lubricated so the shift collar is worn so bad it can not lock it into gear. now remove front and rear driveshafts and 6 bolts hold it to the transmission extension housing it is spline d just like the drive shaft .once out place trans side down and remove small tail housing then remove snap ring then remove larger case half. be careful here the pump hose should be close to the drain plug area and by working the the motor shaft you can see what has too much clearance. go this website: www.Transtar Industries .com they have a exploded view on your transfer case .



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