99 Explorer Tranfer Case Grinding Forward

[CP1]

New here, so “Greetings from NW Iowa”
Customer brought his Explorer XLT 4.0 with grinding in Auto and 4X4 High forward gears , but okay in reverse and 4 Low
80000 miles on it. Replaced the transfer case motor and still the same. When I had the motor off, I could manually shift with a Vice Grip and seemed to work without grinding on the lift. Reading some of the problems other have had, sounds like shift forks and range slider??
Wondering which tranfer case is in this 99? Tag is broke off, so is there a way to identify? What do you think about the grinding noise?
Thanks

 

[wollimann]

Wondering which tranfer case is in this 99?

Is a Borg Warner 4405 transfer case, which cause some trouble like chain too long, fork plastic inserts gone, range slider, worn out rear bearing seat, broken spring, ...

https://www.explorerforum.com/photopost/data/503/DSCN7258.JPG

G

How to: Thread 'The Borg Warner 4405 Transfer Case Rebuild Diary'

March 16, 2007

I am going to try and put this entire thread together much as I did the 4R70W Diary, so those just needing basic info do not have to sift through a lot of chatter throughout the thread. I will create and link another comment thread for those comments - which is here:

http://www.explorerforum.com/forums/showthread.php?t=182072

and until at least the first half of this Diary is done, lock this thread. (unlocked for now as the first half is done)

Much of this initial info came from the FORD manual, with some edits. While the initial part might not make a lot of sense to some...

• Glacier991
• Replies: 138
• Forum: Transmissions & Transfer Cases

 

[410Fortune]

Sounds like the control trac 4wd is out
Drain t case fluid and check it for any small white nylon bits
Very likely time for a rebuild or replacement

Can consider a control trac delete if the customer plans to keep this 99
Control trac delete would ditch the control trac 4405 t case and install a ranger 1354 in its place (non awd) there is some wiring to do otherwise it physically bolts in