An abnormal noise may develop from the transfer case. At this time parts are not available to repair internal damage to this type of transfer case, replacement is the only option. It is not uncommon for irregular tire wear to cause a similar noise. Diagnoses should be performed to confirm the actual cause of the driveline noise. Tire noise can be reduced by rotating the tires at least every 5000 miles.Google+
Car Problem Reports
Ford Escape Internal Transfer Case Problem on the 4WD models
Ford Escape Problem
Model Year Affected: 2005
Drive Train Affected: 4WD
Visitor, 2005 Ford Escape, 4WD
TRANSFER CASE - CAN BE REBUILT... IF YOU TAKE IT APART YOU CAN GET NEW SEALS IN THE USA BUT NOT IN CANADA. MY MECHANIC IN DOMINICAN REP - WHO WAS AMERICAN. REBUILT THE TRANFERS CASE. THE PART THAT WENT WAS A GEAR ON A SHAFT - HE HAD IT RE-LEVELED AND PRESSED AND WELDED AGAIN AND MACHINED IT. WHICH COST ONLY 20 BUCKS IN THE DR. BUT WILL PROBABLY BE 200 IN THE USA. THE BEARING WERE EASY TO FIND AT A LOCAL BEARING SHOP AND WE USED VOLVO PREMIUM GASKET SEAL WHEN WE PUT IT BACK TOGETHER. NOTE- DONT BE CHEAP AND TRY NOT TO BUY THE SEALS - IT DIDNT WORK. I BOUGHT THEM AT FORD FOR ABOUT $150. ITS BEEN 2 YEARS NOW AND ITS STILL A SOLID REPAIR. IT TAKES ABOUT 12 HR LABOUR AND 3 HOURS TO REBUILD THE CASE WHEN U HAVE THE PARTS- AND YOU WILL DEFINITLEY NEED TO USE A LIFT..
Toothed gear in the transfer case could break loose on it's shaft. It creates a loud noise. Ford doesn't sell internal parts for the transfer case, only seals. Unfortunately you need to replace the entire transfer case.
Make sure your wheels/tires are the same size and rotated in every oil changes. Even a small difference on the tires overall diameter will put lots of stress to the transfer case.
Dealer can't part. It's been 4 weeks now and part is still on back order.