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1996 Explorer (5.0 V8 AWD) transfer case question

Discussion in 'Explorer & Ranger Transmissions, Transfer Cases, &' started by rcc510, June 15, 2009.

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    1. rcc510

      rcc510 New Member

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      Trying to help a friend track down some information. He's got a 96 Explorer as per the title and I was under the impression that the transfer case is a BW4404, but I'm having trouble looking it up with the service manual software. After choosing the 1996 Explorer and looking at the specs they show a BW1354, BW4405 and a Dana TC28.

      Also, the 4404 seems to have been used in certain explorers between 96-98 so I dug around in the software some more to look at the 1998 Explorer w/ AWD. It certainly LOOKS like a BW4404, but doesn't give the option to look for specs (make/model). Anybody know if the removal and disassembly/assembly instructions for the 1998 Explorer AWD transfer case from the Ford software apply to the 1996 Explorer AWD?

      Thanks in advance
       
      Last edited: June 15, 2009
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    3. rizzjc

      rizzjc Scubajoe - Radio Mod Staff Member Moderator Elite Explorer

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      Yes, the BW4404 is the AWD transfer case. But I thought that in '96 they got the V8 in the Explorer, but not yet the AWD transfer case. I thought all of the 5.0 '96 Explorers were 2WD.
       
    4. rcc510

      rcc510 New Member

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      Pretty sure his Explorer is AWD, but I'll double check!
       
    5. rizzjc

      rizzjc Scubajoe - Radio Mod Staff Member Moderator Elite Explorer

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      The 4405 is the Control-Trac transfer case in the V6 Explorer. Not sure about the 1394. Are you sure that's right? A search on the site doesn't turn anything up.
       
    6. rcc510

      rcc510 New Member

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      Definitely not sure as I'm not that familiar with these vehicles, but I'm going off what the software is saying. After selecting 1996 for the year and then Explorer for the model it then goes to a 1996 Aerostar/Ranger/Explorer sub window. Choosing Group 07: Transmission I see 5 choices for the transfer case 07-07A through 07-07E

      07-07A Transfer Case 4x4 System Service which mentions 1354 and 4405
      07-07B Transfer Case mechanical shift mentions 1354
      07-07C Transfer Case electronic shift mentions 1354
      07-07D Transfer Case control trac mentioned 4405
      07-07E Transfer Case E-4WD mentions the Dana TC28

      I noticed I made a typo in the original post and edited it RE: 1354
       
    7. rizzjc

      rizzjc Scubajoe - Radio Mod Staff Member Moderator Elite Explorer

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      OK, yeah, 1354 sounds better. I believe that's an older one. Someone else would have to comment on whether or not it was in a '96, but definitely NOT if it's a 5.0L V8. The 4404 is the only transfer case that would be in the V8, but again, I am pretty sure that wasn't available until '97. Maybe someone else with more information will comment.
       
    8. rcc510

      rcc510 New Member

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      Is it possible a 97 model was purchased in late 96? Just trying to figure out the discrepancy as it is definitely the 302 (5.0L V8) and AWD ...
       
    9. Halvey_1530

      Halvey_1530 New Member

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      I am having trouble finding which transfer case I need too. I am 100% positive my Explorer is a '96 XLT AWD with the v8 5.0 but everywhere I have checked gives me mixed information. So the 5.0 V8 was available in '96, would that mean it is the 4404 then?
       
    10. PopRichie77

      PopRichie77 Well-Known Member

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      The new models come out from Sept. to Dec. If the door sticker says manufactured in Sept. to Dec. It is probably the new model. Manufactured in Sept.-Oct.-Nov.-Dec. 96 would be a 97 model.
       
    11. rizzjc

      rizzjc Scubajoe - Radio Mod Staff Member Moderator Elite Explorer

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      I don't think anything but the 4404 ever matched up to the 5.0 in the Explorer. I didn't think the '96 came with AWD, but I think I've seen a few people who did have one, so maybe they came late in '96 model year. My '97 was purchased in mid-'96 and is sorta halfway between a '96 and a '97.

      Bottom line, if you have a 5.0, and AWD, you need the BW4404.
       
    12. OneLever

      OneLever Active Member

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      Make sure the the vehicle is off and in park and the parking brake is on. Then crawl under the driver's side towards the middle of the vehicle. You don't need to jack it up.

      On the right rear side of the transfer case should be an identification tag secured by one of the housing bolts. Below are pictures of my tag with links to higher resolution images.

      Picture 1: Rear view of the transfer case.
      [​IMG]

      Picture 2: Closeup of the identification tag.
      [​IMG]

      These are from a 1997 5.0L AWD with a build date of 07/1997 according to the driver's door jamb sticker.
       
    13. Halvey_1530

      Halvey_1530 New Member

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      Thanks that should help a lot
       

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