Transfer Case Problem?

jknapp6 · July 12, 2003

Help!

I started have a noise when deaccellerating (sp?), however when I shift into neutral the noise stops. Also I notice if I keep the speed 45 mph or under I do not have a problem it only happend when I am 50 mph or over and comming to a stop, the noise happens.

Does this sound like the transfer case? I t does not seem to be the transmission but I found this thread and it talks about the transfer case.....http://www.explorerforum.com/forums/showthread.php?s=&threadid=80983

What do you guys think? Is it something I can repair? should I take it to the dealer?

Thanks in advance!

jknapp6 · July 12, 2003

Bump

Help help help!

Worried about my X!

mrboyle · July 13, 2003

The noise is most likely the t-case. There have been several people that have had the same problems. Here is a thread about it: http://www.explorerforum.com/forums/showthread.php?threadid=41647

jknapp6 · July 13, 2003

Thanks Mike!

I am checking into it!

jknapp6 · July 14, 2003

mechanic is checking it out!

A mechanic friend of mine is checking it out (he works for a ford dealer)...

Anyway i have done some research and here is some of what I found:

Link to the article in gears magazine ( a must read):
www.gearsmagazine.com/2002-09/2002_09_60.pdf

Link to a transfer case identification doc:
www.atra.com/mar2002/2002-03_26.pdf

Link to the company (Rockland Standard Gear Inc.) that remanufactures the transfer case:
www.transmissionsandtransfercases.com

I called this company and they quoted me a price of 1095.00 for the transfer case 200.00 core charge and 75.00 shipping to my door. They say that Ford will not acknowledge that there is a transfer case problem, but they rengineer the transfer case so that the problem truley is fixed!

Let me know what you think!

mrboyle · July 14, 2003

The price of their case is about $700 less than a new one from Ford. For that price I'd go for it.

jknapp6 · August 1, 2003

Rebuilt my Transfer Case!

Just finished rebuilding my transfer case and road testing it!

For just over a hundered dollars in parts (Bearings, seals, fork, shaft (that the fork rides on), shaft and cam (that moves the fork) and a gasket.

Oh and two quarts of Mercon automatic transmission fluid for the transfer case and two quarts of Mercon V automatic transimission fluid for the transmission.

It seems to work fine so far but only drove it about 5 miles, but i did get it up to about 60 miles an hour or so to see if my noise came back and it did not.

AlaskanJack · August 1, 2003

Oh that was cheap, was it difficult?

jknapp6 · August 3, 2003

Nope!

The hardest part was getting the bolts out of the case itself.... you know what two unlike metals do, so be careful getting the bolts out

Other than that it was easy!

section525 · August 3, 2003

So you rebuilt a 4405? Have anymore info on that? Did you get your parts list from your Ford buddy? I have a 4405 in my garage that I would like to freshen up! Thanks!

jknapp6 · August 3, 2003

Yes I got to look at the Service manual for my ford and it had the parts list and we ordered all the parts we thought we neeeded ahead of time, so we could take the transfer case out of the X rebuild it and get it back in the X and on the road.

Again it was not hard the most important thing is not to break the case if you do you are sunk, so when splitting the case do not drive a screw driver between the to pieces. there are several spots with tabes you can use to pry it apart with a bar.

If you have any specific questions just let me know!

oh and I have ordered a manual for my X on cd from www.flatratetech.com!

macanudo56 · August 14, 2003

jknapp6, that was a great job!

You have read me on another thread, wondering if I would swap to a 1354 or rebuild the 4405. I always thought that if the second was to be done, then it was worth to give it a try and rebuild it myself. Now your example really encourages me to do so.

Just two questions:

1) In your replacement parts list you don't mention the range hub. According to the "Gears Magazine" guy, this is the part that should be making the ratcheting sound due to its teeth being worn out. Did you change it?

Note: This is the second time my t-case fails and the first time the range hub was replaced for being worn just like they say in the magazine. I still keep the old part...

2) What about the case holes where the fork shaft is held? Were they worn? The article says it is useless to repair the t-case unless this problem with the holes is corrected, since it is the single cause for all of the trouble. Did you take any actions on it?

Hope to hear from you soon

Luis

hardazz04 · September 10, 2003

Allright sorry to butt in but I have almost the same problem but i get that loud winding noise when im under 45 mph and when I come to a stop.. any knowledge on this since you figured out urs?

jknapp6 · September 11, 2003

luis-

sorry I did not get back to you sooner but have been very busy!

Not sure what the range hub is but there was no problem with the holes where the fork shaft connects with the case either top or bottom. What I replaced is the fork (the plastic inserts were worn) the fork shaft (scared) and the cam that goes on the fork shaft, it was worn.

This transfer case had 100,000 miles on it!

now....

Hardazz04-

Not sure what to tell you that is the same thing I had.

I dropped the transfer case off the X and tore it apart and rebuilt it. Now I have a friend that works for a Ford truck dealer here in town and he let me look at the ford repair manual and we ordered all the parts and then rebuilt it with his help!

If you have any questions let me know!

hardazz04 · September 11, 2003

allrighht I appreciate it--- im not going to tackle my t case till I get all the water out of my tranny!!!!

I sunk my expo under six ft of water

jknapp6 · September 12, 2003

Bummer!

Well any good luck and I hope you get it all fixed up!

briantf · September 13, 2003

Parts list in flatratetech?

Is the same parts list you used available from flatratetech? I think I'll be buying a used 4405 to rebuild and swap in to my wife's truck.

Regards,
Brian in CA

jknapp6 · September 13, 2003

YES! it is....

I bought a cd from flatratetech and it is the same, very helpful too!

good luck!

I am going to be out of town till the 22nd so i will not be able to answer till I get back!

Billy177 · September 17, 2003

i would say thst you should check your cv joints as they may be on there way out also

macanudo56 · September 18, 2003

Hi Jon,

The range hub is the gear that has a disc on it, where the plastic inserts of the fork sit. When the shift motor moves the fork, it drives the range hub, so you get 2WD, 4WD AUTO, 4WD LO (or other settings according to the model). It's interesting to know that there were no problems with the fork shaft holes in your transfer case. However, a worn fork or shaft could cause by themselves the misalignment the guy in Gears Magazine talks about.

I look forward for you to be back and tell us how the t-case is behaving so far. If you have any photos of the rebuilt, it would be nice to have a look at them...

Keep in touch,

Now...

Hi Hardazz04,

Excuse me for being back to you so late. Ratcheting on deceleration and coasting is most likely the transfer case. A worn gear will be expelled from engaging as power applied decreases, causing the ratcheting sound. As long as you keep your foot on the gas pedal, the gear stays in mesh and everything will run OK. Sooner or later this will get worse and you'll have to repair it. Sorry to hear about your X having a dive. While you check your tranny for water, don't forget to do the same with the differentials and if you haven't started the engine yet, remember you MUST be sure it is absolutely dry before attempting to start it. Otherwise you could hydro-lock it and cause a most severe damage to rods, pistons, crankshaft. Just let me know when you decide to tackle your t-case.

Best,

Luis

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