4wd shifting issues - transfer case

[Fix4Dirt]

You have 2 shifting positions, and a clutch. He doesn’t. He has 3 positions, no clutch. His case shifts between 2 and 4hi. And also from 4 hi to 4 low.

Your cases are only similar in bolt pattern. They are entirely different otherwise.

ah shoot. another differecne i didnt know about if the shift motors swap over though, how is the shift done from2-4h? ive been wrong a heckuva lotta time recently dont know what to say bout that

 

[Mbrooks420]

It changes position, just like when selecting low, except it engages the front drive, and not shifts a set of planetarys.

 

[Fix4Dirt]

It changes position, just like when selecting low, except it engages the front drive, and not shifts a set of planetarys.

alright, that sounds familiar maybe i should stay off when my brain is fried, has been the past few weeks which coincidentally was about when i started to be wrong more often just gotta get thru 2 more weeks of finals

 

[307explorer]

This truck has always made a bit of a click (module) and a bit of a clunk (tcase) going into 4wd ever since it was new.
We had a tcase rebuild of some sort about 5 years ago(truck belonged to family member then who doesnt remember the specifics).

Since the rebuild it hasnt made much noise going into 4hi but 4lo it still clunks pretty good.

Last night I put the truck in the air and everything seems to be working as it should, except going back into 2hi. I cannot get it to magically "unlock" like i wanted it to. I am going to take the shift motor off and mess with it a little more, i dont expect any changes.

Today I am attempting to remove the front drive shaft, to hopefully drive it in 2hi until i get a new tcase.

This is like the one time in years I havent had an extra vehicle. I thought the ford was good enough to daily for a while, I mean hell I wasnt actually using the 4wd or beating on it at all. I was easily interstate driving and it just randomly slipped in at the end of my trip.

You don’t need to remove the case.

So i really hope you are right, I do not want to remove rear drive shaft and tcase just to get the front one off.
Prepared to do it i suppose but I would like to avoid

 

[Mbrooks420]

This truck has always made a bit of a click (module) and a bit of a clunk (tcase) going into 4wd ever since it was new.
We had a tcase rebuild of some sort about 5 years ago(truck belonged to family member then who doesnt remember the specifics).

Since the rebuild it hasnt made much noise going into 4hi but 4lo it still clunks pretty good.

Last night I put the truck in the air and everything seems to be working as it should, except going back into 2hi. I cannot get it to magically "unlock" like i wanted it to. I am going to take the shift motor off and mess with it a little more, i dont expect any changes.

Today I am attempting to remove the front drive shaft, to hopefully drive it in 2hi until i get a new tcase.

This is like the one time in years I havent had an extra vehicle. I thought the ford was good enough to daily for a while, I mean hell I wasnt actually using the 4wd or beating on it at all. I was easily interstate driving and it just randomly slipped in at the end of my trip.


So i really hope you are right, I do not want to remove rear drive shaft and tcase just to get the front one off.
Prepared to do it i suppose but I would like to avoid

I’m 100% positive. I’m not sure why this concerns you so much. I’ve never seen a driveshaft on a typical 4wd that needs the t case to come out to drop the driveshaft. It’s 6 bolts around the CV , and 2 U joint straps. Remove those 10 fasteners and it’ll all but fall out.

 

[307explorer]

I’m 100% positive. I’m not sure why this concerns you so much. I’ve never seen a driveshaft on a typical 4wd that needs the t case to come out to drop the driveshaft. It’s 6 bolts around the CV , and 2 U joint straps. Remove those 10 fasteners and it’ll all but fall out.

Thats music to my ears. I will have to take it out regardless when I change it, I just dont have a great setup to do it today.
In a few weeks I will have access to a lift and another vehicle

Thank you mucho Mbrooks and everyone else who chipped in. Really appreciate all of the assistance

 

[oklagp1200r]

alright, so i was on the right track of M vs E.

and i think that only appleis to 4lo. i cant hear a thing going to 4hi

You should here that shift motor shift that transfer case from 2W to 4Hi like on my 2001

 

[Fix4Dirt]

You should here that shift motor shift that transfer case from 2W to 4Hi like on my 2001

maybe youve got the 1354 as mbrooks mentioned , ive just got 2/4Hi, and 4lo. 2-4hi is just a clutch

 

[307explorer]

Found a used bw1354 out of a sport trac at the local yard for $200.

 

[leighton75]

hate to restart an old thread but ... my wife uses a 95 eb 4dr 4wd to deliver mail in . i am a little confused on the transfer case.
according to the tag it is a bw4405 under the transfer motor it has H-N-L the dash switch had 2wd 4h and 4l. should i be able to
turn the front shaft freely in 2wd or not. i get about an inch of play on the chain and the hall sensor above the motor is pretty wore down so i figure it is time for a rebuild. just wanting to make sure it is the right case for this model and someone previously just slapped it on in a hurry.

 

[410Fortune]

95 explorer should say control trac awd in the tailgate
And uses an early version of the 4405 control trac torque on demand transfer case

Your dash switch should say 4auto 4hi and 4low I believe but it’s possible the radio bezel has been changed over the years trying to fix switches or issues? Other models are 2wd 4hi and 4low

Your speedometer is driven by the sensor with driven gear above the shift motor that is the vehicle speed sensor (vss)

 

[wollimann]

1995 Ford Explorer 4.0 OHV 4WD, CAD front axle with vacuum, Borg Warner 4405, switch 2wd,4x4high,4x4low
1997 Ford Explorer 4.0 SOHC 4WD, DANA35SLA front axle , Borg Warner 4405, switch Auto,4x4high,4x4low, TOD
(my state of knowledge)

should i be able to
turn the front shaft freely in 2wd or not.

With tires on the ground i would say no.

The best rebuild diary

How to: - BW 4405 Transfer Case Rebuild Diary - Comments, Questions and Input Thread

Lead in to the 4405 Rebuild Diary Questions and Comments Thread (below) Well, I have a slew of pictures of a BW 4405 TC disassembly... now I need to educate myself to explain what's in them. Ya know, everyone starts somewhere in learning new things. I do and have freely admitted I know...

www.explorerforum.com

 

[Mbrooks420]

95 explorer should say control trac awd in the tailgate
And uses an early version of the 4405 control trac torque on demand transfer case

Your dash switch should say 4auto 4hi and 4low I believe but it’s possible the radio bezel has been changed over the years trying to fix switches or issues? Other models are 2wd 4hi and 4low

Your speedometer is driven by the sensor with driven gear above the shift motor that is the vehicle speed sensor (vss)

In 95 and 96 they were 2wd, 4auto and 4 low.

 

[leighton75]

i have 2 95' s with the 4405. on 1 the front shaft spins with all tires on the ground . 1 doesn't when i disconnect the front shaft from the tc it will spin. so i am guessing that the 1st one needs a chain

 

[410Fortune]

The 95-96 v6 trucks also have a cad front diff… so don’t forget to check its function… cad is center axle disconnect… there is a solenoid on the passenger cv axle that engages and disengages that cv axle. Went away in 97. Also I believe the 95 and early 96 tod transfer case is slightly different in operations from the later 97-01’setup