Ford Ranger/Explorer E-4WD help. (longish, sorry)

[CaseyJ955]

I was offered a 1997 AWD Aerostar XLT van for $200 from my parents business so I picked it up and drove it home with 125k on the clock. It was the last year of Aerostar and the only year to get the 4.0 and 5 speed auto. I never realized how much more stomp the 4.0 has over the 2.8, 2.9 and 3.0, all of which I have owned previously in Rangers. As some know the Aerostar is not a minivan, it's built on a Ranger/Explorer frame with many parts interchangeable. It's an enclosed light truck more than a minivan. I loathe minivans, always have. This one gets a pass for 4wd and body on frame construction.

 

I know Rangers and Exploders are everywhere and a few of these had this E4WD systems. I'm hoping a member here has experience with one, or some working knowledge of their operation/repair/trouble spots.

 

What happened:

I drove it home at night, dry roads. It ran and rode surprisingly well, the 4.0 has so much more stomp than the smaller V6 choices. Once on my gravel road I stomped the gas from a stop to test the 4WD system. There was no detectable tire spin, just a pretty hard launch for a heavy loaf of steel with a V6. Anyways, this vehicle came with 14" steel rims (OEM) and 3 different tire sizes, courtesy my late nephew who bought it briefly after it was taken out of service. It was driven hard like that for a few days before Dad took it back. Young Lake did exactly what I would have done at that age. I know he's watching me deal with it and I can feel his apology in my bones haha. I sure miss that kid. I sort of think of this van as being his so there is a twinge of sentimental value here.

 

Today I was moving firewood and tires with it in 4" snow, it got pretty ugly trying to go back up the icy hill. It was not doing what an AWD/4WD should do. I cancelled the OD and eventually/reluctantly it clawed up, I'm not sure but it felt like the fronts were trying to do their thing, and maybe towards the end they were helping a little, but sure not as it should. So I suspect the transfer case is shelled from tire choices, but it did work in gravel just as it should. It almost feels as if the cold was preventing correct operation for whatever reason along the lines of wear or damage. I was alone so I couldnt see if I had mad front wheel slippage, it didnt feel like it but the front tires are in very sad shape. I went to the wrecking yard this morning and grabbed a set of aluminum 16" Explorer rims to upgrade from the 14" steelies to use some studded snows I have laying around for my Lexus, which being a correct wheel drive is a zero in the snow regardless of tire choice. Today when I drove it was just here and on snow/ice. It's never been off the property since I noticed the tire sizes.

 

I'm having trouble finding any information on operation/repair of this Electronic 4WD system. Common faults? Some sources say the case has spider gears, others say clutch packs, others still say fluid coupling. I doubt the later. I'm hoping that someone here has a Ranger/Exploder with experience using the E4WD system. The owners manual is shockingly vague. Says use the switch (if there is one) and youll see the light (if there is one). I cant see hub assemblies, looks like an Full Time 4WD with a transfer case that can switch on/off connecting the fronts. I'm not sure if the front driveline rotates all the time, but I dont see any front hubs, manual or otherwise.

 

Whats the real skinny on these systems? If it's not a terrible fix I'll do that and leave it alone. I may not even be understanding the operation of it. It was emphasized that this is NOT an AWD, but an electronically controlled honest 4wd system. I think it's a gray area myself. I read that the fronts kick in only in the event wheel slippage is detected. If that is the case than maybe the xfer case was spared, unless the different tire sizes created the illusion of slippage to the van and it tried to engage the fronts, eating itself form the inside out.

 

I would like to fix it and leave it as OEM if feasible. I'll replace it with a manual Ranger/Exploder Xfer case if it goes that far. If I have to pull the case it's getting swapped out with a manual case from a Ranger. It would be a plus right now to have some real information on this system before I dive into it.

 

I understand how 4wd systems work, and how they differ from AWD, and I know there are many different AWD systems and I understand how most of those work too. This particular system is new to me and not much online information. Any light anyone can shed on these systems would be fantastic. TIA!

[djh3]

Maybe this post will help. Fellow says the tranfer case is PCM controlled when it senses when there is wheel slippage. If the front diff is limited slip, my best guess would be its a clutch pack type. Seldom is there a limited slip in the front diff.

[CaseyJ955]

Maybe this post will help. Fellow says the tranfer case is PCM controlled when it senses when there is wheel slippage. If the front diff is limited slip, my best guess would be its a clutch pack type. Seldom is there a limited slip in the front diff.

 

I saw that thread while searching but I cant get to it. The link goes 404, I tried to search it out with terms and I just cant get there. I dropped it off in town this morning where it will receive the aluminum OEM 16" Explorer rims and four studded 225/60/16s. If I cant get it up my driveway tomorrow when I pick it up I'll know it's a Tcase and not a traction issue.

[Sylvester]

You do realize that taking it up in wheel size and possibly tire size you will lose a lot of "stomp" from it.

 

[CaseyJ955]

You do realize that taking it up in wheel size and possibly tire size you will lose a lot of "stomp" from it.

 

 

Yup, but I spect' it may balance out the speedo haha. The factory tire size is 215\70\14 which is charted as a 25.9" diameter, wheres the replacement snows would have a diameter of 26.6" I expect to feel it but I dont expect it to be significant. For the summer I'll look at which sizes 16" come in a diameter close to OEM.

[CaseyJ955]

It sure looks and rides better with 16s, but the 4WD is not functioning at all, no light or anything. If luck is on it's side the 4WD system was disabled the whole time it had all the mismatched tires, as it seems to be now. I guess it's time to find a manual and do some troubleshooting.