4WD light flashing and 4WD will engage after few minutes

4 Wheel Drive will not engage properly,it will engage after few miles.

PROBLEM:----

• 4 WD will engage after driving 2 miles or so it makes a bang type noise and tries to engage into 4wd on it's own.
• 4WD light flashing.

SOLUTION AND TROUBLESHOOTING FOR THESE PROBLEMS:----


As per our garage repair experience we have seen man vehicles with such problems.

The most common problem is with your free wheel clutch system, specifically either a faulty solenoid pack or damaged hoses going to it, etc.

WHAT EXACTLY HAPPENS?
When the free wheel clutch solenoid pack goes bad or hoses to it are damaged, it will allow the front axle clutch to slide in small increments.

NOW,
Once it moves a few millimeters, the detection switch will show it out of position in comparison to the shifter range and the light will come on/flash.

SO,
If the clutch actuator is allowed to go too far (especially noticeable on deceleration, but can be random) the front axle will fully engage.


So to repair these issue,few possible parts needs to be inspected ..........

• Inspect the freewheel clutch solenoid hoses for any damage then test the solenoid itself. 

For your information the freewheel clutch solenoid is located on the right hand frame rail beneath the air filter.
With the help of volt meter you should have about 43 ohms across either coil, and you should be able to allow/disallow air from passing through each as voltage is applied/removed to each coil. If any of those tests fail, the solenoid pack needs replacement.

With our garage repair experience its issue with free wheel clutch solenoids, at our garage  we change these free wheel clutch solenoid packs out on a weekly basis. Even having been redesigned a dozen times over the past 20 years, they still all fail eventually and have the same symptoms you describe.
Verify your hoses first for damage, then test the solenoid pack.
If hoses looks worn out,then dont hesitate to replace the hoses too.

These details will help.
Thanks.

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2-WHEEL DRIVE & 4-WHEEL DRIVE Replacement?

The details are for Ford 4wd and 2wd.
4 wheel drive and 2 wheel drive.
This procedure will work for
Lincoln Aviator, Ford Explorer, Exp Sport, Exp Sport-Trac, Mercury Mountaineer 2000-2005


Removal & Installation
2-WHEEL DRIVE
4-WHEEL DRIVE

The instructions with proper details and diagrams is as follows :----

1. Before servicing the vehicle, please familiarize yourself with safety procedures.
   
   WARNING

   Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight of the driveshaft can pinch the boot between the driveshaft and the constant velocity (CV) joint flange which can cause the boot to tear.
2. With the vehicle in NEUTRAL, position it on a hoist.
3. Index-mark the front driveshaft to maintain driveshaft balance.
4. Remove and discard the 6 CV-joint bolts and CV-joint washers.
5. Remove the 4 universal joint strap bolts and remove the universal joint straps. Discard the bolts.
6. Remove the front driveshaft.
   
   WARNING

   The can (domed CV-joint housing cover) is pressed into the CV-joint housing at the factory. When housed correctly, the can will appear as shown in the illustration. Do not reseat the can in the CV-joint housing if the can's flange is above the CV-joint housing as shown in the illustration. Install a new driveshaft.
   
   
   
   WARNING

   Tighten the CV-joint bolts evenly in a cross pattern or damage will occur to the CV-joint.
   
   
   
   NOTE

   Install new CV-joint washers and CV-joint bolts. If new CV-joint bolts are not available, coat the threads of the original CV-joint bolts with Threadlock and Sealer TA-25 meeting Ford specification WSK-M2G351-A5.
   
   
   
   NOTE

   Install new universal joint strap bolts. If new universal joint strap bolts are not available, coat the threads of the original universal joint strap bolts with Threadlock and Sealer TA-25 meeting Ford specification WSK-M2G351-A5.
   
   
   
   NOTE

   Verify that the universal joint bearing caps are seated in the pinion yoke flange before tightening the universal joint strap bolts.

To install:

1. Installation is the reverse of the removal procedure. See the accompanying illustrations for torque values.

Fig. Front driveshaft exploded view

Fig. CV-joint installation-front driveshaft

Fig. Front driveshaft CV-joint torque sequence

2-Wheel Drive

Fig. Rear driveshaft exploded view-2-wheel drive

Fig. Rear driveshaft flange torque sequence

1. Before servicing the vehicle, please familiarize yourself with safety procedures.
2. With the vehicle in NEUTRAL, position it on a hoist.
   
   NOTE

   Make sure the index marks on the extension housing and driveshaft are aligned before separation.
   
   
   
   NOTE

   After removing the driveshaft, place an index mark on the transmission output shaft that matches the transmission extension housing mark.
3. Index-mark the driveshaft and the extension housing to maintain driveshaft balance.
4. Index-mark the driveshaft flange to the pinion flange to maintain driveshaft balance.
5. Remove and discard the 4 driveshaft flange bolts.
   
   NOTE

   The driveshaft flange yoke fits tightly on the pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft flange from the pinion flange.
6. Use a suitable tool and pry only in the area shown to separate the driveshaft flange yoke from the pinion flange.

To install:

1. Installation is the reverse of the removal procedure
   
   WARNING

   The driveshaft flange fits tightly on the pinion flange pilot. To make sure that the driveshaft flange seats squarely on the pinion flange, tighten the driveshaft flange bolts evenly in a cross pattern.
   
   
   
   WARNING

   If new driveshaft flange bolts are not available, coat the threads of the original driveshaft flange bolts with Threadlock and Sealer TA-25 meeting Ford specification WSK-M2G351-A5.
2. Tighten the flange bolts to 83 ft. lbs. (112 Nm).
   
   
   

   

   Fig. Pry at this point only

4-Wheel Drive

1. Before servicing the vehicle, please familiarize yourself with safety procedures.
2. With the vehicle in NEUTRAL, position it on a hoist.
3. If equipped, remove the skid plate.
4. Index-mark the driveshaft flange to the transfer case rear output flange to maintain driveshaft balance.
5. Index-mark the driveshaft flange to the pinion flange to maintain driveshaft balance.
6. Remove and discard the driveshaft flange bolts.
7. Remove and discard the transfer case rear output flange bolts.
   
   WARNING

   The driveshaft flange fits tightly on the axle pinion flange pilot and the transfer case output flange.
   
   
   
   NOTE

   Never hammer on the driveshaft or any of its components to disconnect the driveshaft flanges from the mating flanges. Pry only in the area shown, with a suitable tool, to disconnect the driveshaft flanges.
8. Using a suitable tool as shown, disconnect the driveshaft flanges and remove the driveshaft.

To install:

1. Installation is the reverse of the removal procedure
   
   WARNING

   The driveshaft flanges fits tightly on the pinion flange pilots. To make sure that the driveshaft flanges seat squarely on the pinion flanges, tighten the driveshaft flange bolts evenly in a cross pattern.
   
   
   
   WARNING

   If new driveshaft flange bolts are not available, coat the threads of the original driveshaft flange bolts with Threadlock and Sealer TA-25 meeting Ford specification WSK-M2G351-A5.
2. Install new fasteners. Torque the flange bolts to 83 ft. lbs. (112 Nm).
   
   
   

   

   Fig. Rear driveshaft exploded view-4-wheel drive

This will help.

Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html