Transfer case VSS gear question

[feel lucky]

Originally Posted by Glacier991

Another excellent thread Drew. Thanks.

I read your rebuild diary(well done!) looking for the answer to a question-
Cruising down the highway and my speedometer dropped to zero.
My VSS gear was worn out so I have new VSS and new 20 tooth gear from Ford. Parts dept at Ford told me to check the VSS gear in the transfercase because it will likely be worn out also. So here's the question-Can I check the transfercase nylon gear without taking it out and is what the parts department told me true in your experience? If it has to be replaced can it be done without pulling the TC?
Also-what causes the VSS to wear out? Failure to change lube? Guilty as charged!
This is on a 1995 4x4 XLT Explorer with 170,000 miles, automatic trans and 4WD "on the fly" on the dash panel. Fluid has never been changed, only topped off occasionally. Not sure which TC I have but can take a look after work tonight. No other known issues with transfer case. One question turned into many. I would appreciate any helpful suggestions.

[IZwack]

Post extracted form T-case Fluid Change thread.

[feel lucky]

Okay, so I needed to get the Explorer back on the road and not getting a quick answer to my questions I took a chance and put the new VSS with new gear back in my TC-which as it turns out is a Borg Warner 44-05. With a mirror, flash light, and digital camera set on macro zoom I could see that the TC internal VSS gear was a bit mangled and the VSS didn't exactly slide in easily but it went. Next step was to drain the black sludge out of the TC-wow! I'm totally embarassed to admit I let it go so long as I'm pretty regular with other maintenance. I mistakingly assumed since the 4x4 is not usually engaged it wasn't getting much wear. After reading up on the VSS function on this forum I now understand it's always turning if the vehicle is moving. Want to post pics I took of the process but haven't figured out how. I'll work on that.
I would still like to hear from someone knowledgeable about replacing the internal VSS gear in the BW4405. I know it needs to be done and what I did is probably temporary at best but had to get it back on the road.

[jwrezz]

I'm in the same situation myself. o/d lite flashes. trouble code P0500. Pulled out sensor and it looks ok. Is the nylon gear going to come as part of the replacement sensor? I think it's just the gear that's bad, but I want to replace the whole sensor. That nylon gear looks a bit worn, but I don't know how good the thing that drives it is. Truck runs like sh!t w/out this sensor functioning properly. Shifting is messed, and I can tell it's going to effect mileage big time. Pulling the sensor off makes it worse, so for now the bouncing speedo, and slightly bad sensor is better than no sensor. Any one else have experience w/ this situation?

[feel lucky]

I bought the sensor at O'Reilly's for about $13 and it did not come with the new gear. Went to Ford and got it for about $4. At the base of the gear is a number indicating the number of teeth and "R" or "L" indicating right hand or left hand orientation. Best best take the gear with you when you go get the new one and verify it.
After I replace it everything has been working great-smooth shifts, etc.

[jwrezz]

Great, thanx, feel_lucky!

[bmyers]

I went through the same problem and replaced the gear on the VSS but it quickly got chewed up also. I found a replacement for the gear inside but I need to know if I have to pull the transfer case to replace it or can it be done with it still in the truck?

I have the 6 cyl 4wd sport trac 2 door model.

Thanks,
Bill

[jwrezz]

Originally Posted by bmyers

I went through the same problem and replaced the gear on the VSS but it quickly got chewed up also. I found a replacement for the gear inside but I need to know if I have to pull the transfer case to replace it or can it be done with it still in the truck?

I have the 6 cyl 4wd sport trac 2 door model.

Thanks,
Bill

Ditto! New gear is getting chewed up and speedo is bouncing around again. I've seen some pics of the gear inside the transfercase. It doesn't look good. I'm really wanting some external way to get the VSS or some equivalent to work and send a signal to the computer as needed. I heard of some thing for GM trans' I think, but not for this set up. Maybe? Any one?

[bmyers]

Well I was able to find the drive gear and replace it without removing the transfer case. But the new speedometer driven gear is getting chewed up again VERY quickly, within miles. Didn't see any nasty stuff in the fluid I drained out but my hopes are fading fast here. Speedo gears are getting hard to find and I'm suppose to take this thing on a family vacation in a few days. Replaced the sensor just for the heck of it. Don't know if thats going to help at all.

ANY HELP IS APPRECIATED..

Thanks,
Bill

[feel lucky]

Bill,
Wish I had an answer for you but I would love to know how you replace the transfer case gear!

[drdoom]

Originally Posted by feel lucky

Bill,
Wish I had an answer for you but I would love to know how you replace the transfer case gear!

It's been a while, but as I recall: Disconnect battery. Raise, support, & chock vehicle. Mark & remove rear drive-shaft at transfer case, set aside. Remove companion flange from output shaft, discard nut (30MM socket) & small seal, keep washer. Remove VSS. Pull & discard main output seal, gear should be right there.
Best wishes.

[bmyers]

Note to Self: Best guess on chewing up new VSS gears, your transfer case is shot. A loose output shaft will move out of alignment and chew up the gears. Once the gears go, the truck wont know when to shift anymore. You're stuck on the side of the road or in limp home mode.

Bill

[IZwack]

Originally Posted by bmyers

Note to Self: Best guess on chewing up new VSS gears, your transfer case is shot. A loose output shaft will move out of alignment and chew up the gears. Once the gears go, the truck wont know when to shift anymore. You're stuck on the side of the road or in limp home mode.

Bill

True - but I want to point out (to future readers) that this applies to 95 and 96 in the 2nd gen world. 98+ Explorers takes speed/shift readings from the rear axle.

[AgInternational]

It's been a while, but as I recall: Disconnect battery. Raise, support, & chock vehicle. Mark & remove rear drive-shaft at transfer case, set aside. Remove companion flange from output shaft, discard nut (30MM socket) & small seal, keep washer. Remove VSS. Pull & discard main output seal, gear should be right there.
Best wishes.

I am just about to replace the speedo gear inside my BW 1354 manual TC I just need to get the seal. i have read some threads that give instructions and some with pictures and i think I know how i can do it. 2 questions though; my fluid is fairly new so do I have to change it?

This thread sums it up pretty well, just replace the gear in before you put the new seal in.

http://www.explorerforum.com/forums/...d.php?t=211785

[4X4 Explorer]

Originally Posted by bmyers

I went through the same problem and replaced the gear on the VSS but it quickly got chewed up also. I found a replacement for the gear inside but I need to know if I have to pull the transfer case to replace it or can it be done with it still in the truck?

I have the 6 cyl 4wd sport trac 2 door model.

Thanks,
Bill

Make sure you are getting the correct driven gear. Two transmission suppliers sold me the wrong gear. If you have original...take with you to Ford dealer.
Also my TC BW 4405 on '96 Control Trac must be split to replace the driving gear...so I am told. Anyone with different info?