1998 Ford Explorer Transfer Case Slop?

Question

I have a 1998 Ford Explorer AWD V8. When I start to accelerate from a stop it takes a second for the front drive shaft to start to spin and it clunks when it begins to turn. It's not a loud clunk, but noticeable. I work at a GM dealership and one of the technicians and I put my truck in the air and found that there is a little slop in the front shaft. It's not from the U-joints. It's coming from inside the transfer case. What part would need to be replaced in order to fix this? I don't feel like replacing the transfer case because most of the ones I've found are $500 or more. It's not that bad of a problem, just annoying, and my tech said it's just a piece of s*** Ford and I should deal with it, obviously he's a GM guy. Is it worth replacing parts, and if so what part would most likely cause a little too much play in the front drive shaft, or is it a better idea to buy a remanufactured transfer case?

Answer 1

It's the exact same Borg Warner t-case that GM uses, so tell your buddy not to comment if he doesn't know what he's talking about. It's an excellent unit. GM used it in the Typhoon.

It has a chain driven, viscous clutch inside. I would check that.

Answer 2

I have a 98 explorer but its' 4wd not awd my problem is it's clunking when driving more when going uphill. I opened the transfer case and found out that the hi/low gear collar is worned out and also the shifter guide. I replaced it and the clunking went away.