Across the Pond Transfer problems

[Andyharry666]

Hi everyone, new to this so excuse any mistakes.
I've got a 1999 4.0 V6 Auto explorer that I suspect has a failing Tx case(BW4405). The vehicle developed a grinding noise from the front end that was at first intermittent but gradually got worse. It has proved very difficult to isolate and the only thing I had to go on was that it was worse when in 4X4 (I have Auto,4x4hi & 4x4low). I have since removed the front driveshaft (prop shaft to us brits) and the noise has reduced 90%. From reading every post on the subject I can find I am almost convinced its the T case but as this is the uk and the spares are not as readly available I'm a bit nervous of taking the plunge and dropping the unit for closer inspection. Does anyone think I'm correct in my analysis ??
Another question is how long would it be possible to run the truck without the front driveshaft, I've got it switched to 4x4 as this will stop the t case thinking I have no forward traction is this a good idea? I've got a trip up to Scotland next week with my boat and if I can't fix the T case I'm considering going with only the rear driveshaft Anyone out there who's done anything similiar?
I'd be thankfull of any advise anyone could give me.

Cheers

Andy

 

[Glacier991]

While I am on a steep learning curve.... I've a ways yet to go. Is your 4405 an AWD unit or a control-trac unit? If the former, I understand you can kill the viscous coupler by driving for extended periods without the front driveshaft installed.

 

[IZwack]

Since you already have the propshaft removed, move the front pinion yoke (the yoke that the propshaft bolted to) on the front differential and see if there is any lateral free play.

 

[Andyharry666]

Thanks for the response guys.

Glacier991: The Tcase is the control-trac unit
IZwack:The yokes solid with no lateral movement

A

 

[Glacier991]

In your case driving w/o the front shaft won't hurt anything. I am working on a Rebuild Diary on the 4405 Control Trac, just need to pop the $250 US for new case halves to rebuild it. It is in the stickies section above. (Finish coming soon)

 

[Andyharry666]

Thanks again G, it looks like the holidays back on. I'm hoping to get my hands on a decent second hand TC so that I can swap them and overhaul the original. Risky I know but there's no one over here who seems to stock refurb units. Like to say your Diary is great, hurry up with the rebuild I'm going to need it!!!!!!!!!!!!!!! I'll post some pic's when I do it,to show what I find !!

 

[Andyharry666]

Success (sort of !!!!)

Just a quick update..
I found a junk yard unit 50k miles from a 99 xlt which had been rolled and was an insurance write off. I've just finished fitting it and the noise is gone. Only one snag being that is won't engage 4X4 low . Ive yet to drive it in anger though so it may engage once I'm able to drive it on a more suitable surface. Wish me luck