My Front Differential has failed.

You have AWD? full time all-wheel drive.
Transfer Case Description and Operation
The Borg Warner (BW) model 4481, RPO NR3 transfer case is a one-speed, full time, all wheel drive (AWD), transfer case. The transfer case provides power to both axles, through an external planetary type differential, which has two different sets of pinion gears. The planetary differential provides a 40/60 torque split, front/rear, full time. This means both axles are constantly being driven for maximum traction in all conditions.
The transfer case external type planetary differential functions the same as a typical rear axle differential. The transfer case differential pinion gears function as the spider gears, and the sun gears function as the side gears.
The following actions occur because of the planetary differential:
• If the vehicle is on a hoist, the front propeller shaft can be rotated by hand.
• The vehicle cannot be driven if one propeller shaft is removed.
• Operating the vehicle on the hoist can damage the differential pinion gears, by over-spinning.
• Operating the vehicle with one propeller shaft removed causes over-spinning of the differential pinion gears.
The BW 4481 design of the planetary differential allows the use with the Vehicle Stability Enhancement System (VSES) vehicles. The VSES takes use of the planetary differential, by applying braking to a tire that has less traction and dividing the engine torque to the other axle.
The BW 4481 case halves are high-pressure, die-cast magnesium. Ball bearings support the input shaft, the front output shaft, and the rear output shaft. The transfer case requires DEXRON®III ATF GM P/N 12378470 (Canadian P/N 10952622), which is red in color.

This system does not have an encoder motor.

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Elaine,

not work, do tell what makes you think it dont work (a lamp) or tires slipping or dead tires. (by tires mean that and traction)??????????

what mode fails, of the many, and where.???????



first off, we dont know what your tires are touching.

on road, or off road. pavement or ICE or snow.

that matters big time . (you read manual and match MODE to Road)

your lost operators guide explains all that, right?

eg: how and when to use, 4wd, its all there. I promise.

ControlTrac 4-wheel-drive system



here are the mode. which one , gives you problems.



quote ford with comments.



What are the modes, and how do they differ?

(note this is the operational behavior of a 2008 Ford Expedition. Newer and older Expeditions will vary only slightly)



• 2H 2-wheel-drive with high range gearing (1.00:1) Rear-wheel-drive capability,

2-wheel electronic traction control system is enabled



• 4A 4-wheel-drive Auto with high range gearing (1.00:1) Full-time all-wheel-drive capability, ((best on pavement or any time)

Electronically adjusted torque split to front & rear wheels, Electronically variable center differential,

Front driveshaft & rear primary driveshaft allowed rotational speed difference,

4-wheel electronic traction control system is enabled



• 4H 4-wheel-drive with high range gearing (1.00:1) Part-time 4-wheel-drive capability, (not for dry pavement EVER)

Continuous 50/50 torque split to front & rear wheels, Electronically locked center differential,

Front driveshaft & rear primary driveshaft mechanically locked with no rotational speed difference,

4-wheel electronic traction control system is enabled



• 4L 4-wheel-drive with low range gearing (2.64:1) Part-time 4-wheel-drive capability, (off road usage, mostly)

Continuous 50/50 torque split to front & rear wheels, Electronically locked center differential,

Front driveshaft & rear primary driveshaft mechanically locked with no rotational speed difference,

4-wheel electronic traction control system is enabled, ESC and RSC are disabled



In 4A mode the center differential is electronically-controlled and rear drive wheel bias. The on-board computer monitors for any sign of rear drive wheel slip (loss of traction)

If loss of traction is detected, the center differential is told to send a share of the engine\'s torque to the front drive wheels. It will not let the front driveshaft turn at the same speed as the rear driveshaft.



What about traction management?

1997-2002 model Ford Expeditions offered an optional limited-slip rear differential (LSD). A conventional open rear differential was standard along with the conventional open front differential and the electronic locking center differential.

comment with out LSD, one tire can spin, on say ice.

but the other 3 tires dont, in full time.

The Selectable Four Wheel Drive (S4WD) Front Axle consist of the following components:
• Differential Carrier Housing
• Differential Case Assembly
• Inner Axle Shaft
• Intermediate Shaft Bearing Assembly (located on the right side of the oil pan)
• Electric Motor Actuator
The front axle on Selectable Four Wheel Drive (S4WD) model vehicles uses a disconnect feature mounted on the right side of the oil pan in order to engage and disengage the front axle. When the driver engages the 4WD system, the Transfer Case Control Module sends a signal to the electric motor actuator to energize and extend the plunger inside. The extended plunger moves the clutch fork and clutch fork sleeve across from the clutch fork outer gear that is splined to the right side wheel drive shaft to the clutch fork inner gear that is splined to the inner axle shaft. The locking of the two gears allows the axle to operate in the same manner as a semi-floating rear axle. A propeller shaft connects the transfer case to the front axle. The differential carrier assembly uses a conventional ring and pinion gear set to transmit the driving force of the engine to the wheels. The open differential allows the wheels to turn at different rates of speed while the axle continues to transmit the driving force. This prevents tire scuffing when going around corners and premature wear on internal axle parts. The ring and pinion set and the differential are contained within the carrier. The axle identification number is located on top of the differential carrier assembly or on a label on the bottom of the right half of differential carrier assembly. The wheel drive shafts are completely flexible assemblies consisting of inner and outer constant velocity CV joints protected by thermoplastic boots and connected by a wheel drive shaft.

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The fluid splattered all over is most likely coming from the pinion seal. (The seal at the front of the differential where the driveshaft yoke goes in.) Normally, you would remove the driveshaft and the pinion yoke to relace the seal. The grinding however, leads me to believe that the seal leaking is a RESULT not a CAUSE of your problem. The way you describe it sounds like you may have some serious pinion and/or ring gear damage inside the differential.
If this is the case, there are severl ways to go about repairing this. You could tear your differential apart and replace the defective/damaged parts inside. You could replace your differential with a used one from a salvage yard. You could replace your differential with a remanufactured differential assembly.

To check for damage, remove the rear cover from the differential and check for metal in the oil and in the bottom of the housing. You can also turn the ring gear around and check for broken teeth. You can also inspect the spider gears and pinion gear for damage.

2000 GMC TRUCKS SSERIES JIMMY 4.3L 6-cyl Engine Code [W]
Differential, Front......GL-5 All TEMPS......80W-90 Manufacturer recommends GM part no. 1052271 or equivalent Do not add limited slip additive.
Differential, With 7.25 RingGear Front..........1.2 liters
Differential, With 8.25 RingGear Front..........2 liters
Differential, With 9.25 RingGear Front..........2.8 liters

Your car has what is called a transaxle. This is the transmission and traditional differential in one unit. There is no actual differential per say.

Typically operation noise will occur if the output gears are failing. It will be noisier on the deceleration than the acceleration. This is usually a whining noise. Sometimes this can be jerky during operation.

All of the instances you mentioned can cause a transaxle unit to fail.

you have to pull out the front axles to get the gears out of the differential

Here are the Fluid CAPACITIES & MORE:
Engine, with filter..........4.6 quarts[1]
Cooling System, Initial Fill..........12.0 quarts
Automatic Transmission, Total Fill
4 speed 4L60, 60E..........11.0 quarts
Manual Transmission, NV1500..........5.7 pints
Manual Transmission, NV3500..........4.2 pints
Differential, with 8.6 ring gear Rear..........4.0 pints
Differential, with 7.25 ring gear Front..........2.5 pints[2]
Differential, with 8.25 ring gear Front..........4.2 pints[2]
Differential, with 9.25 ring gear Front..........5.9 pints[2]
Differential, Front..........2.5 pints
Differential, Rear..........4.0 pints
Transfer Case,BW4472..........2.5 pints
Transfer Case,NV136/236/246..........4.0 pints
Transfer Case,NP207..........4.6 pints
Transfer Case,NP231, NP233..........2.3 pints[3]
Transfer Case,NV231/233..........2.1 pints[3]
1. After refill check oil level.
2. Do not use synthetic lubricant in axles using RTV sealant.
Synthetic lubricant will chemically atack RTV sealant.
3. Identification: check tag on case.

Not complicated but too long to write. You can get a manual from chiltons, haynes etc that has good instructions for this. Likely if you are reasonably good with tools, you could figure it out. Most important part of the job is getting a differential with the exact same gear ratio to match the rear. (usually there is a metal tag on one of the cover bolts or count the number of teeth on both the ring gear & pinion gear.) Make sure axle tubes are the same length and don't forget to bleed brakes when you are finished. Need any help along the way, just ask...I'm here!