treydestepheno
Member
- Joined
- February 3, 2010
- Messages
- 26
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- City, State
- MTY, MX
- Year, Model & Trim Level
- 1984 bronco II
1996 explorer xlt with a bw4405 part time electric shift TC
transfer case wouldn't come out of 4x4, front cad would disengage allright, but the front shaft would spin no matter what. we drained the TC and found copper wires in the oil (a lot of copper) we pulled the TC off to open it.
we don't know what caused what exactly, so I'm just gonna list off what we found:
the electromagnet had unwound, and a lot of the copper wiring was AT THE BOTTOM of the TC (transfer case must have grounded up a lot of it)
what was left of the copper wire in the electromagnet was bunched up to one side (as if pulled by friction)
the clutch (the "electromagnet actuator" according to http://www.explorerforum.com/forums/showthread.php?t=182071 ) was fused to the output shaft at an angle. and it was cracked.
we pretty much had to destroy it to get it out, but since it was cracked to begin with, who cares.
and lastly, the bottom disk where the three little balls rest was also cracked.
we have almost no resources (THANK YOU ECONOMY) to get a new TC, we're going to a junk yard later today to see what we can find. if things go badly, our plan is to gut the inner components of the TC except for what is necessary to run the output shaft. that way at least we'll have a working 2x4 vehicle. (until we get it fixed, the TC will work as a bridge between the transmission and the rear shaft)
the X is our only family car and we can't have it out of commission for very long. I'm open to all suggestions. Do you guys think the plan of leaving only the components necessary to transfer power to the rear will work?
transfer case wouldn't come out of 4x4, front cad would disengage allright, but the front shaft would spin no matter what. we drained the TC and found copper wires in the oil (a lot of copper) we pulled the TC off to open it.
we don't know what caused what exactly, so I'm just gonna list off what we found:
the electromagnet had unwound, and a lot of the copper wiring was AT THE BOTTOM of the TC (transfer case must have grounded up a lot of it)
what was left of the copper wire in the electromagnet was bunched up to one side (as if pulled by friction)
the clutch (the "electromagnet actuator" according to http://www.explorerforum.com/forums/showthread.php?t=182071 ) was fused to the output shaft at an angle. and it was cracked.
we pretty much had to destroy it to get it out, but since it was cracked to begin with, who cares.
and lastly, the bottom disk where the three little balls rest was also cracked.
we have almost no resources (THANK YOU ECONOMY) to get a new TC, we're going to a junk yard later today to see what we can find. if things go badly, our plan is to gut the inner components of the TC except for what is necessary to run the output shaft. that way at least we'll have a working 2x4 vehicle. (until we get it fixed, the TC will work as a bridge between the transmission and the rear shaft)
the X is our only family car and we can't have it out of commission for very long. I'm open to all suggestions. Do you guys think the plan of leaving only the components necessary to transfer power to the rear will work?
