4405 removal and reinstall.

[97sprt4x4]

I will either tomorrow or sunday be pulling my 4405 and replacing it with another 4405. i've searched and i haven't found quite what i'm looking for. i was just wondering if anyone could tell me if it's as easy to take out as i think. from what it seems like there are 3-4 bolts connecting it to the transmission, and that's the only thing holding it up. then i remove the front and rear drive shafts unplug the plugs and place the newer one in it's place and reverse the removal process... is it really this easy?? will i need to replace any fluids?

thanks in advance,
Justin

 

[gmanpaint]

You pretty much got the just of it. Skid plate(if you have one) first, shift motor(zip tie to frame rail), disconnect harness, speed sensor(think yours on your case) drive shafts, unbolt from transmission(top bolt is a bear, might have to leave in stab hole), slide backwards off trans spline, lower with jack. It will be lighter with fluids and counter weight removed, can bench press it down if strong enough(aprox 75 lbs). 8, 10, 12, 13 mm is all you will need, the gear wrenches are the bomb for this job.

Some like to use a gasket or rtv when replacing it to the trans tail housing. Some trans fluid can get into the tail housing. Replace old fluid if newer t-case is used. Mobile 1 trans fluid is a great oil to use in your new one. Might want a little locktite on your drive shaft bolts, or check them often after install.

1.5 hrs, and you should good to go.

 

[97sprt4x4]

will i have to replace the trans fluid or the transfer case fluid???

 

[gmanpaint]

will i have to replace the trans fluid or the transfer case fluid???

I would put in new fluids in the new T-case. I use Full synthetic Mobil 1 trans fluid in it, 1.5 qt (aprox) before it starts to trickle out the fill hole.

You wont lose any trans fluid during the swap., But while your under there it might be a good time to service it.

 

[97sprt4x4]

kinda really hoping the trans doesn't need anything. i don't know if you remember but a month ago i was having issues... i had the whole thing rebuilt with a shift kit. so it should be golden. less then a 1000 miles on the rebuild. but thank you for the advice i'm hoping everything goes smoothly tomorrow and i can be out wheeling tomororw night.

 

[97sprt4x4]

the case is in and works. i think you either have some kind of understanding that i don't possess smaller hands then me or people helping you that have done it before. it took me approximately 5 hours to complete but it's very worth it, i think i'll be reversing the brown wire mod to keep myself from trying to do what the truck is incapable of doing. also i think the trans in my truck is a little different i lost about a quart of transfluid in the swap. hope this helps someone else in the future.

thanks for your help.

Justin

 

[gmanpaint]

Not sure what you mean by smaller hands.

I'm glad you got in & it is working.

Mine is most likely easier to change because I have a 3" body lift, more room to work on it.

You must have had a lot of trans fluid in the tail house to lose a QT swapping it out. The trans fluid can leak past the rear seal into the tail house, perfectly normal, and why some choose to use a stock gasket from the dealer.

Congrats on doing this yourself, small percentage of people would even try.

 

[97sprt4x4]

well i lost a qt because there is a small valve in the tail housing that i would suppose connects to the trans pan that lets the fluid travel between the two and it kept dripping out. but in any case, i'm very glad that i got it done. me a friend did this and it was quite an adventure getting the bolts out as well as getting the case back up into position with it being only 10 inches from the floor. thanks for your help gman!

Justin

 

[kimball]

I have a 97 AWD with 250K. Put in reverse after driving for an hour and had a big clunk.
Truck would not go f or R. I think it may be the BW 4405. How can i tell? How can i
remove the top bolts in the transfer case to remove it? I must be missing something it can't be that hard to take the trans fer case out. I was going to remove it and see if the trans would spin in gear with out the transfer case. Any help?

 

[kimball]

I have a 97 AWD I can not get the top bolts out of the Transfer case. It seems as though there are 8 bolts holding it to the Trans. How do you get the two top ones out???

 

[gmanpaint]

I have a 97 AWD I can not get the top bolts out of the Transfer case. It seems as though there are 8 bolts holding it to the Trans. How do you get the two top ones out???

There are 3 on top. 1 dead center, 1 at 10, 1 at 2 o'clock.

The top center bolt is a pita. I left it inside the stab hole after backing it out completely. The others shouldn't be that bad to remove, just have to contort & twist you arms & hands to get to it. Try a real long extension with a swivel universal adapter.