Transfer Case Transmission - need help!

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Fitz98

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Just replaced my transfer case in 98 Expedition.
Went for a test drive and transmission would not shift gears (reverse, and drive worked but would not shift out of first and then it stopped moving altogether).
Once stopped had no 2 wheel drive gears at all.
When shifting into park, gears were grinding slightly.
Was able to shift into 4 wheel drive high and 4 wheel drive low gears and got to go in reverse and forward.
Then shift back to 2 wheel drive again and the 2 wheel drive gears came back again, then same problem repeats itself.

Any ideas what is the problem?
 
Did you do the work yourself or did a shop do it? If a shop, take it back. If you did it yourself, make sure everything is hooked up properly. Also, be sure fluid levels are at their proper fill and are you sure you used the correct fluid?

Also, did you disassemble anything when you swapped the transfer case? A buddy of mine did this one time and accidently moved a shift lever on a front wheel drive Buick. Thankfully, there was a little access plate on the side and we were able to remove this plate and pop it back in the right place. Until then, the vehicle would only go into first gear.
 
Did it myself. Fluid levels and types are correct.
Linkages are working, since the problem is an itermittent one and sometimes worked through all gears.
 
The grinding only happened when the vehicle finally stopped moving altogether. I agree that something may not be lined up, but what are the possibilities? The only shaft that had a spline restriction was the front shaft. Everything else slid in without issue...which leads me to a possibility of one of the sensors in the transfer case?
I see 2 sensors, but don't know what they do and how they could affect the 2 wheel drive shifting and operation.
 
Is there a possibility that the shift motor is not fully engaging in a 2 wheel drive mode? If so, would that explain why the transmission would not shift out of first gear? Again, no transmission component was touched in this process, so it seems logical that is is related to the transfer case in some way.
 
Which transfer case did you get?

The earlier Expeditions (like yours) had 2WD. The later ones (IIRC, 2000+) had "AUTO" and no 2WD position. IE, I can't lock my '02 in 2WD, I have AUTO, 4HI and 4LO. You have the 4-position switch, correct?
 
Originally Posted By: Fitz98
The only shaft that had a spline restriction was the front shaft. Everything else slid in without issue...which leads me to a possibility of one of the sensors in the transfer case?


When you say "spline restriction" do you mean you had a hard time getting it back together? Did it bind in any way when you reassembled it? Or did it give you problems and eventually slid in. If it went in hard or difficult, i.e. you had to force it, something didn't go together properly.
 
the output shaft for the front wheel drive a
had a larger groove to mate up with a double spline on the mating shaft. That was the only one that had only one way to install it. All the others had equal splines on all shafts.
 
I am in process to swap all sensors and motor with the original in known working condition. I have noticed quite a bit of material (probably worn metal ...sillvery paste) on the sensors, perhaps that is sending bad information to pcm?
 
Originally Posted By: Fitz98
I am in process to swap all sensors and motor with the original in known working condition. I have noticed quite a bit of material (probably worn metal ...sillvery paste) on the sensors, perhaps that is sending bad information to pcm?

That can cause magnetic sensors to malfunction.

However, my first thought was that when the connectors were unplugged and plugged back in they might not make perfect contact.

Blow off the connectors before plugging them back in, and you might solve the problem.

Did you ever have a Nintendo NES? People who had one tend to remember this trick.
 
Originally Posted By: Fitz98
correct, 4 position switch. All parts match original setup


OK, just making sure. I'd check part #'s from old to new and make sure they all match.
 
This was my thinking as well after taking them out and seeing the accumulation of material on the sensor.
Are those sensors magnetic?
That would potentially explain a lot.
Also do you think the information sent from those sensors plays any part in the transmission shifting (or lack thereof)
 
When I took off the shift motor, I saw the case on both stamped with 2wd, 4H and 4L. I would assume this would confirm there is a 2whel drive position in this transfer case.
 
Well the transfer of parts is done. Will test drive tomorrow, but at first glance, there is a lot less cluncking and major shifting noises when swithching between drive modes.
I don't want to do a real distance test drive at this time, prefer to do it in daylight time.
 
Originally Posted By: Fitz98

Also do you think the information sent from those sensors plays any part in the transmission shifting (or lack thereof)


It certainly can. When the T-case was going out on my Explorer it would suddenly discover "magic neutral" at times, particularly when going from forward to reverse or vice-versa.
 
So here is the latest. Swapped out shift moter and all 3 sensors on the transfer case. Problem still persists. starts and engages in 2wd, erratic, shifting and hard shifting at higher engine rpms, then lose all 2wd modes. Can switch into 4L and then back to 2wd, and about 50% of the time that will get me back into sluggish, erratic 2wd mode again.
Could fluid have anything to do with it not staying in 2wd mode? I did drain and put fresh fluid.

Also want to mention that I did put a light coat of grease on rear drive shaft splines and outside as well, but I am not sure if any of the sensors read against the actual drive shaft itself.

Seems like my next step will be to take both transfer cases apart and inspect all parts to see if I can rebuild 1 good one.
 
Originally Posted By: Fitz98
it stopped moving altogether.
Once stopped had no 2 wheel drive gears at all.
When shifting into park, gears were grinding slightly.
This tells me the T-case is going into neutral. The transmission is happily spinning away with the t-case in neutral until you put it in park and make the park pawl ratchet and bang as if you were still rolling.

Quote:
Was able to shift into 4 wheel drive high and 4 wheel drive low gears and got to go in reverse and forward.

sounds like the rear output is losing its connection to the input shaft (neutral) is this a clutch pack type t-case or gears and sliders?
 
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