99 Expedition 4x4 Issues

Italian Rafter · 11-15-2006, 10:05 AM

I have a 99 Expedition XLT; 4x4; 5.4L:

I've gone to my hometown mechanic and then to two FORD dealerships and they have all told me something different.

Over the weekend, I had to engage the 4wd (on the fly). After I got out of the quagmire, the 4wd would not disengage and go back to AWD. I tried everything, Park, Neutral, Reverse all while trying to get the transfer case out of low range. Then, the whole drivetrain sounded like it was going to fall out (it was binding up), and my spedometer was spiking. Finally, the transfer case just went into complete neutral on both drive shafts. These symptoms sound really bad, but they are detailed just like this on a couple of FORD's TSBs. After a little time, I got the transfer case back to rear wheel drive, but it was like my front wheels had locked hubs (I couldn't turn sharply at all). Come to find out, it's not hubs, but the front driveshaft binding in turns.

I have several FORD Technical Service Bulletins (TSB's) that I've got from the three mechanics I've been dealing with. Some point to GEM module, others to bad grounds, and finally a shift motor (on the transfer case).

Home Mechanic - $50 to test grounds and gem module; paid him.
Ford # 1 - Wanted to charge me $900 to replace the GEM module; I declined
Ford # 2 - Wanted to charge me $1900 to replace the entire transfer case; I was really pissed about this one and declined.

The computers all pull up the same errors: shift motor, shift motor plate, speed sensors in front/rear diff's. When I have the mechanic(s) reset the GEM Module (by clearing the codes), the "HUBS" unlock, or really the front driveshaft doesn't bind, for a short time until you start to drive 25' and then they lock back up. I'm not in Low range, but the front driveshaft binds and the Expedition "thinks" it's in 4HI all the time.

Where I'm at now:
I dropped my front driveshaft and am driving in 4HI (so really just 2wd rear and I don't have the binding)...so I put a bandaid on it. I've ordered a $100 shift motor online and hope this will fix it.

Anyone have any advice or experience with a similar issue like this? Thanks!

divadavidcars · 01-22-2007, 10:39 AM

Where are you at now? Did the shift motor work? I just replaced my shift motor and it did not help. My problem was the AWD does not disengage all the way.

Pedro · 02-21-2007, 09:58 PM

Quote:

Originally Posted by divadavidcars

Where are you at now? Did the shift motor work? I just replaced my shift motor and it did not help. My problem was the AWD does not disengage all the way.

Did you fix your truck all ready? i have ame problem and dont know what to do....

VTRedwolf · 03-11-2007, 07:05 AM

Quote:

Where are you at now? Did the shift motor work? I just replaced my shift motor and it did not help. My problem was the AWD does not disengage all the way.

I have a similar problem. I get this clunk in my front end when I first start accelerating. First thought it was a sway bar, but then noticed it doesn't happen in AWD. Is it possible my AWD is not disengaging all the way also.

puckeater37 · 03-15-2007, 07:03 PM

yeah i have a 99 eddie bauer and whenever i turn the wheel to either right or left. my truck hops and on dry pavement the back tires chirp. its almost like its stuck in four wheel drive but not seeing it on dash. any suggestions?

thurosalsa · 07-15-2007, 08:12 AM

i have the same problem did you fixe your problem any suggestion?