BW4405 bearing replacement

[DAZ97XLT]

So there's no question about it, I have to pull the tc!

97' Explorer XLT Control Trac 4WD.... BW4405 TC

The output shaft is very loose! Drained the fluid and and it's black with some silver dust(pictured) but luckily I don't see metal flakes or any chunks of any kind.... I do see some very small bits of nylon from the guides or what I'm assuming is nylon from the guides... The debris is definitely not metal, I checked with a magnet! Btw I got less than a quart of fluid out of the tc so it's definitely been ran low...

I did find the 'BW4405 rebuild diary' and I'll be referring to that thread when taking my tc apart but I just wanted to open my own thread to be able and focus on mine and whatever specific issue I may run into with it....

I got this vehicle a little while ago and I'm just trying to get it road worthy and I'm also on a budget! I currently have another thread titled 'transmission noise' and I'm finding that almost every bearing is damaged in this drivetrain! I'm still waiting on a bearing kit for the differential and while I wait I'm going to work on the tc!

I only drove this vehicle maybe 10 miles total and the 4x4 low engages just fine! I didn't hear or feel anything that would make me believe there's more issues with the tc than the bearings and nylon guides... If the guides were bad though wouldn't it be hard to shift into 4 lo or 4 hi?? I mean one of the issues it has is hard shifting into gear and I mentioned that in my other thread and it was mentioned that the nylon guides in the tc are probably worn or gone.... I'm currently learning about 4x4's and I don't understand how shifting gears at the transmission relates to the shift fork in the tc, if at all???

So what I'm trying to figure out is what I should get other than a bearing kit for the tc???
I'd like to get all the parts ordered by tonight because time is of the essence but I know I probably won't be able too without taking the tc apart first...
The bearing kit I'm ordering comes with all the bearings and seals and nylon guides, a bushing etc... Here's a picture of the kit I'm getting...

At the moment I'm wondering if it would be a good idea to replace the chain? I wasn't really able to drive the vehicle enough to determine if the chain is an issue though and if I do order a new one it'll most likely be after I have the tc apart because apparently there's different size chains that go into this tc for whatever reasons...

I plan on working on removing the tc today and maybe by tonight or tomorrow I'll be able to determine if the chain has stretched or not and is still useable.....

 

[DAZ97XLT]

Got the tc out!
it's definitely been worked on before!

I saw a video where the guy takes the drain plug out and with a screw driver pushed down on the chain to determine how loose it was so I did the same and it appears to be pretty loose! I can almost pop it off the teeth there's so much play! I've never worked on a tc before so I don't know how tight the chain is supposed to be but I'm assuming I'm right and it needs to be replaced!

Here's a couple of pictures of it...

 

[wollimann]

I've never worked on a tc before so I don't know how tight the chain is supposed to be but I'm assuming I'm right and it needs to be replaced!

In 2013 i do my first TC rebuild with help of a forum and some guys with special knowledge about that stuff.
Until today i learned a lot about that Borg Warner 4405 and now i know the mechanical issues.

The badest issue is the rear bearing seat construction, after a while the bearing seat ovales out,
causing the outer bearing ring to rotate. The more it rotates, the more material will be taken of
from the housing. If the seat is badly worn out the TC main shaft and the rear drive shaft could
begin to vibrate, seal will disturbed and leaving oil out.
Every 4405 has this failure, very expensive to fix this (new rear case or a additional bushing by a mashine shop).

The front TC case has a hole for the shift shaft, ovales out too, brass bushing must be pressed in.

The oil pump has a limited lifespan and could produce micro abreveation particles (sliver shining oil).
The pump "arm" is locked in a case pocket, it goes back and forth so the pocket wears out.
Somme clunking sound could appear.
The oil pump pickup screen could crack.

The shift fork roller could slide out of its guide, an updated shift fork is available or a sonnax repair kit
adressed to this issue. Plastik shift fork inserts wear out, normal.

If you swith to 4x4low and you hear a loud clunk, the range slider ist worn out, maybe the disk has a crack.

If you use the "wrong" main seals (with flange) they could move out a little cause they are not deep enough
inside the case (your ordered set has the matching better seals). TC input shaft seal could be damaged
so automatic transmission oil could move into the TC, overfilled and getting really hot.

Chain gets loose, if too loose it could jump over under pressure. (Two diffent wide chains until 97, and up)

Never had an issue with the clutch or coil, sometimes the TC motor makes some trouble.
To replace all bearings you need a inside bearing puller (for the one small bearing in rear case and the brass bushing)
a puller for the main shaft bearing, do not remeber how the small needle bearing came out, sorry.
Case halfs use RTV, but only a small amout, you don't wanna have silicone in your oil.
First try to get the case halfs together without RTV, cause sometimes there is a 5mm gap leaving.
If so something is not pefectly aligned or wrong installed. Case halfs must slide together easyly,
never use the bolts to get the case halfs together with force.

I hope you will not have all of these issues, take your time to inspect your old transfer case.

regards and lucky wrenching

 

[DAZ97XLT]

Got it apart! The chain is definitely stretched out! It has over 1.5" of deflection !!!!!

That's the least of my concerns with the tc at the moment!

 

[DAZ97XLT]

In 2013 i do my first TC rebuild with help of a forum and some guys with special knowledge about that stuff.
Until today i learned a lot about that Borg Warner 4405 and now i know the mechanical issues.

The badest issue is the rear bearing seat construction, after a while the bearing seat ovales out,
causing the outer bearing ring to rotate. The more it rotates, the more material will be taken of
from the housing. If the seat is badly worn out the TC main shaft and the rear drive shaft could
begin to vibrate, seal will disturbed and leaving oil out.
Every 4405 has this failure, very expensive to fix this (new rear case or a additional bushing by a mashine shop).

The front TC case has a hole for the shift shaft, ovales out too, brass bushing must be pressed in.

The oil pump has a limited lifespan and could produce micro abreveation particles (sliver shining oil).
The pump "arm" is locked in a case pocket, it goes back and forth so the pocket wears out.
Somme clunking sound could appear.
The oil pump pickup screen could crack.

The shift fork roller could slide out of its guide, an updated shift fork is available or a sonnax repair kit
adressed to this issue. Plastik shift fork inserts wear out, normal.

If you swith to 4x4low and you hear a loud clunk, the range slider ist worn out, maybe the disk has a crack.

If you use the "wrong" main seals (with flange) they could move out a little cause they are not deep enough
inside the case (your ordered set has the matching better seals). TC input shaft seal could be damaged
so automatic transmission oil could move into the TC, overfilled and getting really hot.

Chain gets loose, if too loose it could jump over under pressure. (Two diffent wide chains until 97, and up)

Never had an issue with the clutch or coil, sometimes the TC motor makes some trouble.
To replace all bearings you need a inside bearing puller (for the one small bearing in rear case and the brass bushing)
a puller for the main shaft bearing, do not remeber how the small needle bearing came out, sorry.
Case halfs use RTV, but only a small amout, you don't wanna have silicone in your oil.
First try to get the case halfs together without RTV, cause sometimes there is a 5mm gap leaving.
If so something is not pefectly aligned or wrong installed. Case halfs must slide together easyly,
never use the bolts to get the case halfs together with force.

I hope you will not have all of these issues, take your time to inspect your old transfer case.

regards and lucky wrenching

Thanks for the info!
I'm finding that my tc may have all the issues you've mentioned and more!
Here's some pictures of the damage I've found so far.....

The rear output bearing looks good but is very loose in the housing so it's definitely been "ovaled"!!! So now I ether have to find a good case half or a bushing to press in there????
I was hoping for a oow dollar fix but it's not looking too good!

 

[DAZ97XLT]

Should I cancel my bearing kit before they ship it??? I might just have to buy a rebuilt unit now considering how many parts I have to replace and the case being worn where the bearings go!

edit:
Nm! I see that new units are around $1000 and I definitely can't afford that!
I'll just have to find a new housing!
Sucks about the bearings though because they look and feel good! It's just the housing that's worn!
I wouldn't mind trying to find a bushing though if that's an option!!
Can anyone provide a link to the correct bushing for the housing on the rear output shaft bearing?

 

[DAZ97XLT]

It looks like I'm going to be getting a new rear half housing!
I'll probably be $500 into it by the time I'm done...

The clutch pack looks burnt!

At this point I'm looking at a rebuild!!!

From what I can tell the gears don't look damaged!
I'll be posting pics of some parts soon that I want some opinions on whether they're still useable or not...

 

[rogueexplorer1]

I got lucky I had a parts car with 100k less miles with identical parts, so I swapped out the internals. I saw a full rebuilt TC with a 2 year (I think) warranty for $785. Check the tag on your TC. My parts car TC was a 4405-08 & the runner had a 4405-11; the difference being the speedo sensor & the rear case. Make sure you get the correct one otherwise the electronics will not match.

 

[DAZ97XLT]

I got lucky I had a parts car with 100k less miles with identical parts, so I swapped out the internals. I saw a full rebuilt TC with a 2 year (I think) warranty for $785. Check the tag on your TC. My parts car TC was a 4405-08 & the runner had a 4405-11; the difference being the speedo sensor & the rear case. Make sure you get the correct one otherwise the electronics will not match.

Yeah, wish i had a parts Explorer!

Yeah I'm aware of the variations on these cases... I thought I had found a new one(rear half) for $180 on eBay but it doesn't have the port for the speedo sensor...

The thing is I have to buy the parts from either eBay or Amazon because I have credit with them and otherwise can't afford to buy anything at the moment!!!

My last resort might be to go to the local junk yard and pick up a complete unit for $150!
So I'm stuck having to rebuild it using eBay or Amazon parts or just get a junkyard unit and risk that...

I do see lots of used case halves on eBay but there's no guarantee with those! I'm pretty sure it will just have the same problem!

 

[DAZ97XLT]

Here's a picture of the magnet... It's a bit damaged on the inside surface!
Is it still useable???

 

[rogueexplorer1]

Yeah, wish i had a parts Explorer!

Yeah I'm aware of the variations on these cases... I thought I had found a new one(rear half) for $180 on eBay but it doesn't have the port for the speedo sensor...

The thing is I have to buy the parts from either eBay or Amazon because I have credit with them and otherwise can't afford to buy anything at the moment!!!

My last resort might be to go to the local junk yard and pick up a complete unit for $150!
So I'm stuck having to rebuild it using eBay or Amazon parts or just get a junkyard unit and risk that...

I do see lots of used case halves on eBay but there's no guarantee with those! I'm pretty sure it will just have the same problem!

I have the -08 cases that I’m not using & would be happy to ship them to you for free. I also have all the part from the runner that are still good as I think they rebuilt this TC not that long before I bought it. It d be willing to ship you everything for free. Only thing that is busted is the shift arm with no plastic guides. It’s all pretty heavy so packing it up& ship would be a little expensive but I’m willing to help you out by not charging for the parts.

 

[DAZ97XLT]

I have the -08 cases that I’m not using & would be happy to ship them to you for free. I also have all the part from the runner that are still good as I think they rebuilt this TC not that long before I bought it. It d be willing to ship you everything for free. Only thing that is busted is the shift arm with no plastic guides. It’s all pretty heavy so packing it up& ship would be a little expensive but I’m willing to help you out by not charging for the parts.

That's awfully generous of you sir!
It's been a pretty ****ty day finding out how damaged my tc is so your offer is welcome but is any of that compatible with mine? The cast numbers in the housing half I need are 44-05-039-907

I would also only need the rear half of the housing and it's extremely light so shipping shouldn't be more than $25-$30.....

edit: I see that the -08 in your reply was a grammatical error and is supposed to read 98!!! That threw me off!
Are you sure that case is the same one I have?? Mine has three holes for the sensors!

I see in your bio it says you live in Phoenix AZ is that correct?? I have a buddy that lives there! He's actually the reason I ended up with this Explorer! Maybe he can swing by or you guys can meet up and you can give him whatever parts you're willing to give me for free..... I'm feeling a little better about my situation now thanks to your offer!!!!!
I've been on my phone all day and only found one housing half that's the same as mine! It's being sold by 'CobraTransmissions' and it's used so it's risky... They want $130 for it shipped!
If my buddy can't meet up with you to get those parts then I'd pay up to $50 to have you ship whatever you can ship for that amount...

 

[DAZ97XLT]

I have the -08 cases that I’m not using & would be happy to ship them to you for free. I also have all the part from the runner that are still good as I think they rebuilt this TC not that long before I bought it. It d be willing to ship you everything for free. Only thing that is busted is the shift arm with no plastic guides. It’s all pretty heavy so packing it up& ship would be a little expensive but I’m willing to help you out by not charging for the parts.

I made a mistake! I thought I saw that you live in Phoenix AZ but now that I look again it says Oregon not Arizona!
That sucks because my buddy is willing to pick up the parts!!!

Well, If you're still willing to send me some parts I wouldn't mind getting the case from you and whatever else I can afford to have shipped!
I'm sure it'll be the more affordable option anyway...

I'll pm you so we can get this figured out!
I really appreciate the help!!!

 

[DAZ97XLT]

PARTS ID:
Rear half...

Cast #: 44-05-039-907 Rear Half Case

Cast #'s: AZ91D 907 G

Cast #: 7-97


Front half:

Sticker ID #: 44-05-000-012


To be continued...

 

[DAZ97XLT]

Front half continued...

ID#: 44-05-065-910

There's also a 3 cast neer it in multiple locations...

 

[DAZ97XLT]

Damage found:

The chain is very stretched and has over 1.5" of deflection!!!

 

[DAZ97XLT]

Parts I'm not sure about...

This one is the shaft end of the CV to the front axle and is a little worn... Still useable???

 

[rogueexplorer1]

Parts I'm not sure about...

View attachment 465810View attachment 465811View attachment 465812View attachment 465813View attachment 465814


This one is the shaft end of the CV to the front axle and is a little worn... Still useable???
View attachment 465815

Looking through these pics here what I would do. Keep in mind that I'm a 1st timer with this TC so hopefully someone else can read through & verify my thoughts here.

It's totally up to you what you want me to ship. I don't have a scale to weigh anything so the best thing to do is I will suggest what you should replace, verify that with someone of more experience. Then I can find a container to safely hold all the parts & take those parts in the container to a shipping place & get a price. Keep in mind; UPS, FedEx & USPS aren't the only way to ship heavy stuff. I used Old Dominion when I was running a race team here & that can be even cheaper. Just need to see what parts we are shipping & find a container stout enough to hold them. That most likely will be wood of some sort, which will add cost.

You need;
rear half case- you'll need to check how the new bearing fits in there. Mine may be rounded a bit too. The bearing isn't in there anymore.
the clutch plate basket & all the plates
top clutch plate cover gasket- the yellow gasket that's caught in the clutch plates
chain
Speedo sensor & shaft gear
3 ball retainer ring & balls
Magnet ring
Main Shaft- That nut that goes onto that shaft needs to be tightened to 250 ft/lbs of torque so I wouldn't try to just clean those threads up.
Oil pump- mine has a bit of a hesitation in it when you rotate it on the shaft. You can't service this part, have to get new. About $100.
You'll also need to order the shift fork. Get the 1 with the longer bolt end. Have you checked the shaft that the shift fort attaches to? Is the tiny shaft still that holds it into the front case half?

Let me know your thoughts.

 

[DAZ97XLT]

Looking through these pics here what I would do. Keep in mind that I'm a 1st timer with this TC so hopefully someone else can read through & verify my thoughts here.

It's totally up to you what you want me to ship. I don't have a scale to weigh anything so the best thing to do is I will suggest what you should replace, verify that with someone of more experience. Then I can find a container to safely hold all the parts & take those parts in the container to a shipping place & get a price. Keep in mind; UPS, FedEx & USPS aren't the only way to ship heavy stuff. I used Old Dominion when I was running a race team here & that can be even cheaper. Just need to see what parts we are shipping & find a container stout enough to hold them. That most likely will be wood of some sort, which will add cost.

You need;
rear half case- you'll need to check how the new bearing fits in there. Mine may be rounded a bit too. The bearing isn't in there anymore.
the clutch plate basket & all the plates
top clutch plate cover gasket- the yellow gasket that's caught in the clutch plates
chain
Speedo sensor & shaft gear
3 ball retainer ring & balls
Magnet ring
Main Shaft- That nut that goes onto that shaft needs to be tightened to 250 ft/lbs of torque so I wouldn't try to just clean those threads up.
Oil pump- mine has a bit of a hesitation in it when you rotate it on the shaft. You can't service this part, have to get new. About $100.
You'll also need to order the shift fork. Get the 1 with the longer bolt end. Have you checked the shaft that the shift fort attaches to? Is the tiny shaft still that holds it into the front case half?

Let me know your thoughts.

I've never heard about 'Dominion' shipping! I find that USPS is usually the cheapest but whatever ends up happening here it won't require a crate, I'm not gonna have you send me ALL of those parts...

The yoke nut in my application is torqued to 150-180 ft lbs not 250.... It was really easy to get off!
That shaft will be one of the parts I need for sure but if I have no choice I will be reusing mine... I'd rather not but if it works it works!

Let's just assume for now I'll have you send me the rear half and the main shaft, the clutch pack including ball ramp and all the light weight parts you can fit in the box. Speed sensor, maybe the shift motor too.....
Not sure....
Do you know if the chain you have is stretched or not??? Mine is the 1" wide 37 link one...
We'll hopefully get something figured out soon!

Some of these parts I'm looking for are really hard to find like the clutch pack seal, that yellow plastic ring...
The sprocket on the speed sensor itself is also inexistent! I see plenty of sensors being sold without it too! This will be one of the parts I need...

Were you able to confirm all the numbers I gave you match up with the parts you have??????
Can you please take pictures of the rear half case so I can make sure it's the right one???

 

[DAZ97XLT]

Cracked sensor! Is this another part I should replace? Is it just cosmetic or will that crack cause an issue???
This thing is quite expensive! I really don't want to add it to the total if I don't have to!