Transfer Case Trashed on '99 Expedition
 

Collectively, this the brightest place I know (scary thought), so here's a question:

My '99 Ford Expedition with 115K miles on it was diagnosed with a trashed transfer case. Repair costs are roughly $2000. The 4X4 indicator is flashing on the dash. The car is worth maybe $5000. What would you do? This is my daily driver and family hauler.

Options: Fix it (it also needs and AC repair for roughly $500); drive it to Toyota and try to trade it in; etc.

What is the wisest thing to do in this case.
Thanks,
Troy

can you remove the front driveshaft and go 2WD with the TC in neutral, or is it full time 4WD with no shifting of the TC?

Shoot, I'd try to find one at a junkyard and swap the sucker out.

Back when I had my truck (this is years ago) I had a problem with the thing refusing to shift into 4WD, which I wanted for Chicago winter. One less-than-scrupulous mechanic said the xfer case was bad and it would have been a lot of $$$ to fix. Took it to another shop and they diagnosed a "thermal switch" or some such thingy that controls the engagement/disengagement mechanism. $200-or-so later and it was working fine. They got 100% of my business from then on for simply being honest.

I'd get a second opinion. The transfer cases themselves are pretty bulletproof unless you physically crack the case open.

Too bad it isn't an explorer, I would have parts for you.

Sorry for the delay in responding.
The 4X4 system is an "auto" system so the power goes through it all the time. I can't just go 2wd.

I think I will try swapping it out myself. If I can rebuild a 911, I can to a POS Ford, right?
Thanks,
Troy

You should be able to find one pretty cheaply at a salvage yard. Like Jeff said, are you positive it's a transfer case? Other than the 4x4 light flashing, what failure signs of failure are there?

A T-Case is not to hard to replace as long as you have the needed tools.

See what you can get a used one for.

I would at least get a second opinion to verify and then look at other options such as used low mileage unit.

Troy

Might give Todd Dufur at Lockwood Automotive a call. He put a transfer case in our 97 Ford this last summer. Found an excellent used unit and installed it quite reasonably.

Also if the transfer case is not the problem, he'll 'fess up and tell you instead of just finishing the swapout anyway... (honest guy).

angela

Hi Everyone,
I have been struggling with this issue for a few months. The service bulletins called for a replacement of the shift motor. I did so and the problem persisted. I brought the car to a local shop that I trust and they decided to change out the fluid in the T case as a first attempt at solving the problem. When they drained the oil it was full of brass and other metals shavings. The brass was the clutch material. See, this design sees power all the time and the T-case is constantly dividing power front to rear. The T-case only holds two qts of oil and so heats up easily. My understanding is that these Ford auto 4X4 T-cases are prone to failure. So, I am pretty confident it is the T-case.

As far as R&R, the torsion bars have to come out, as well as a cross member. It will probably be a b!tch.

Angela, I'll give Lockwood a call. They are across from the mill so easy for me to get to.
Thanks all,
Troy

Brass?

I replaced the tc in my AWD '02 mountaineer at about the same mileage as yours. Bought a brand new unit from a supplier in Texas - $1200 + shipping I believe. When I first called them they had about 500 units in stock, when I placed my order a month later, they had 3 left. They said they were selling them as fast as they could get their hands on them.

Common problem.

I called the shop that Angela recommened. He's figuring the cost of parts and labor to be about $900. That's less than half of what my normal shop quoted. THats for a low mileage part, not new or reconditioned. Since this is a shoe-string deal anyway (need money to finish my backdate!) I will probably go this way. Thanks Angela!

Hey Jeff; that's what the man said, brass. He claimed it was from the clutches. Heck, I don't know.
Troy

Might have been, just seems odd to me. . . Dunno.

Best of luck to you but I'd either (1) verify it's the case (if there's actually metal shavings it probably is something internal) and (2) whether I can find one used.

I was in the same situation with a 98 expi last year that spit rockers out from under the cam. the truck had 115k on it and the a/c worked great/ However it needed a new head (1k)so I decided to put and junk yard engine (2k low milage)in it my self.. This was my DD as well. After the engine swap from hell (the junk yard engine had the cams timed wrong) I drove the truck a bit more (2000 miles) then sold it for a suburban.. Much happier now. Butif you do a quick calc it was not money well spent

$6k for purchase of Expi with about 108k on it
$2k for replacement engine
3.5 k for trade in this was one of the happiest days of my life and I lost a bunch of money and only drove the truck for 7000 miles....

Jeez Ben!
I'm getting to that point too. I've spent $4000 on this thing for 30K miles of driving. I still need a new steering box (worn out) and AC repairs. Those two are roughly $1000 combined. Maybe its time to go back to Toyota. I've seen four year old Tundras for circa $15K. Great trucks, apparently.
Thanks,
Troy