Discussion in 'Modified 1995-2001 Explorers' started by johnny499, July 28, 2014.
Your pictures are not showing anymore in your build thread :-( Glad things are better now for you.
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Hmmm, Are these 4406 prone to failure? I am on my 3rd, although I cannot blame the T-case for the first one. None of them give the impression of a solid T-case though. I almost went with an Atlas the last time, but someone on this forum sent me one at a pretty good price.
The 4406 was used in trucks with fixed IFS front axles. Could the movement of your front axle be an issue?
Ford used the 4406 up to and including the light duty F250 so I don't think a little EX is going to work one too hard.
You might just have bad luck or your doing something wrong.
Sorry, I didn’t mean to thread hijack.
My first 4406 was the one that was in the rig when I bought it from nnsj2. It died when 3 of the 4 front driveshaft CV bolts backed out and the CV wedged itself against the body of the T-case and split the front drive section off of the T-case. Obviously not the T-cases fault.
The second one I sourced myself from Pick-a-part. After about 10K miles it started making some strange noises on a freeway drive while towing. I pulled over and shifted it thru the gear ranges to see if something was half way in gear. It stuck itself in to low range and I could not get it back out. Much more stranger noises on the 10 mile drive home.
The 3rd one is still working fine, but all of these T-cases had some significant backlash from coast to drive. They all have a “meshing” sound when driving down the road.
I run a slip yoke on my front driveshaft and I do not believe that this is related to any of the issues I am describing.
I have owned a few chain drive T-cases before (NP208, 1356 and whatever is in my 1992 F350). All of them gave a good solid feel, operated noise free unless the chain was in need of replacement and had no notable coast to drive backlash. That is why I am always wondering if the 4406 is the weakest link in my drive terrain.
I have my second 4406 in the garage along with whatever I thought was salvageable from the first one. Someday I will tear apart #2 and figure out what happened. If possible, put it back together as a spare. I have a feeling that if I ever need a spare, it will only be in there long enough to order an Altas.
I was just wondering if there was allot of history with failures on the 4406. For now I still take my wheeling in to the deep dark depths of Rubicon and Dusy-Ershim.
I don't know about the durability, my first one made it 40k for me and that was a junk yard take out with unknown mileage. Both of mine seem to have backlash which may be amplified by the trutrack in the rear end for me. It's nothing like my ranger was with the lockrite locker, that would confuse the cruise control when it crested a hill...
It is what i expect for $125 vs. $2600 for an atlas, i have thought about a 203/205 doubler but that's time and money too.
is it possible to throw up a few detailed pictures of your SAS and suspension? I know photobucket isnt working well for us.
I use https://cubeupload.com and works pretty good for posting pictures.
I will try to get the pictures up soon. lot's of uploading to do. I think i have come up with a bit of a redneck solution to raising the front end for now. i was going to cut the spring pockets and lower them but the way i welded on the plate for the steering gear mount is going to make that difficult to say the least. My plan is to make a spring pocket spacer out of steel and try that for a while.
All photobucket pictures are fixed (that would show up for me) and uploaded to the forum. I did not upload the cubeupload.com photos to the forum as they work fine. If you would like, you can upload the photos directly to the forum to ensure the the photos are here to stay! This build is amazing which is the reason why I took the time to fix these photos. It is a very thoroughly documented build with great fab skills and tools!
Thank you very much Sir!
You are welcome
What software are you using?
Wow!! That's incredible, Thank you so much for taking the time to do that.
The tube bending software is Bend-Tech pro. As it turns out they are a local company. It has changed how i build things for sure.