97 Sport Transfer case replacement options

[Unglar]

Hi, I am working on a 97 Sport 4.0 Auto with the 4405. I beleive the electric motor and clutch are shot. The owner has a very limited income. Initially the vehicle would not go into reverse, there would be a grinding sound from the transfer case. By the time I got it, it will not move at all, any gear causes a grinding noise from the transfer case. I pulled the motor but it is quite a bit different than the one in the motor rebuild thread. I tried manually shifting it, then realized it is full time 4wd and there is a clutch that controls how much power goes to the front an back tires. If I turn the control all the way to the right the rear shaft engages and cannot be turned by hand. If I understand correctly the rear shaft should be engaged regardless of the control position, this leads me to beleive the clutch is shot.
I have read that this transfer case can only be replaced by a same year case. I am wondering if there is a cheap manual replacement or a way to make this full time 2wd?

 

[gmanpaint]

Welcome to the forum.

Your friends 97 has a unique (4405 -GA) t-case because of the front output and the VSS in it.

You can use a (4405-CA) t-case from a 95-96 IF you use the matching front drive shaft that they used. These have the VSS in it as well. The rear drive shaft will fit it, so just keep the old one to use.

Other option is to go manual t-case. A 91-97 Explorer 1354m will work. A few Ranger years have them also. The shifter linkage is the hard part of the swap, as most people do not think to keep it with the t-case when pulled.

Keep searching the forum for more threads on this topic. Lots of info here up for grabs

 

[Unglar]

Thanks for the quick reply! I have read alot of the threads on transfer cases, including the rebuild thread, thats how I know about the clutch. I pulled the case today and will be tearing it down a bit to see if I am right about the clutch and see if there is any other damage. If I understand correctly the VSS is the clutch system and the 95-96 are a bolt in with the proper front drive shaft. Does that include the electrical plug? I thought I read that the 96 is OBDI and the 97+ are OBDII?

How can I recognize the 1354m when I am crawling under rigs? On this one there was a legible sticker (how lucky is that). I beleive I read a thread about disconnecting the dash lights with the manual case, I would probably just set it to 2H and not bother with linkage.

 

[gmanpaint]

If I understand correctly the VSS is the clutch system and the 95-96 are a bolt in with the proper front drive shaft. Does that include the electrical plug? I thought I read that the 96 is OBDI and the 97+ are OBDII?

VSS is the Vehicle speed sensor. 95-97 4405's come with it. 98+ 4405 do not have a VSS.

The plugs are the same for all 3 years.

95+ are all OBDII as far as the transmissions and t-case goes.

How can I recognize the 1354m when I am crawling under rigs?

No sensors on the 1354 t-case like the 4405 t-case has.

4405 sensor

VSS on the case

1354 manual shift. Rear of case showing the output flange & the VSS. Notice there is no shift motor or shift rail. The 4 posts are for bolting the dampening weight.

What happens when a clutch pack goes in a 4405

 

[Unglar]

Update: I picked up a 1354m from a '94 Ranger for $110 with 30 day warranty. It bolted right up. The gasket was only available from the Dealer and was only $6. The VSS plug matched. I got the 1354m from a parts place so no linkage or front driveshaft. I put it in 2H and will leave it there until I can find the linkage and proper front shaft. Hope to get the current front shaft off today, soaking the front bolts in PB blaster, hate those torx screws!

 

[Unglar]

Update: Front drive shaft is off and the owner is happily driving her 2wd explorer. Thanks for your help GMAN!