BW 4405-08 vs BW 4405-11 Transfer Case

[rogueexplorer1]

I’d pull the shift motor and manually shift ranges. Make sure it’s in high range. Be careful doing this alone as the truck may roll.

So, pull the motor, shift the TC into H & shirt through the trans gears, correct?

 

[wollimann]

I should hear a slight knock when it goes into 4LOW, correct?

Correct

But those plates don't get activated until it's switched to 4WD, correct?

Correct

It went into reverse after 5 or so seconds & then slightly backed up a little & then stopped.

Too much time to get in reverse, reverse has the highest oil pressure, there must be something wrong with your automatik transmission pressure. What about the other gears, 2nd and first, no movement?

Regards

 

[rogueexplorer1]

Correct

Correct

Too much time to get in reverse, reverse has the highest oil pressure, there must be something wrong with your automatik transmission pressure. What about the other gears, 2nd and first, no movement?

Regards

All gears are the same, no movement.

I’m thinking this is tranny too. I guess the shops diagnoses was only partly correct? They said replace the T. & all would be good.

I also think about when the TC went down, I could still shift & drive it, even reverse by putting it neutral, shifting to 4Low and then putting it back in Auto then drive& it worked fine. Something just isn’t makin sense here.

 

[wollimann]

Something just isn’t makin sense here.

Yes, such issues are boring. But thinking back/forth/up/down do not give you the answer.
Make sure all fuses are ok, all plugs are together, all ground wires are ok, enough tranny oil, no trouble codes.
Measure current on TC shift motor powersupply and the brown wire.
The automatic transmission issue is the more complicated problem, why does it not shift,
electrical or mechanical problem.
I am not a tranny expert, but the 5R55E could have a lot of issues.

I am "feeling", it is a power supply issue...

 

[rogueexplorer1]

Yes, such issues are boring. But thinking back/forth/up/down do not give you the answer.
Make sure all fuses are ok, all plugs are together, all ground wires are ok, enough tranny oil, no trouble codes.
Measure current on TC shift motor powersupply and the brown wire.
The automatic transmission issue is the more complicated problem, why does it not shift,
electrical or mechanical problem.
I am not a tranny expert, but the 5R55E could have a lot of issues.

I am "feeling", it is a power supply issue...

1st start up, immediately put it in drive & it had enough to nose it into the garage. Pulled the shift motor off & switching it to low rotates the motor. Triangle Shift Arm only rotates a little off of H but won't go to N or L. I disconnected the shift motor connector & tested the brown wire coming into shift motor with a chassis ground & it reads 1.65V? I'm about to start testing the power supply & see if the tranny shifts without the TC shift motor like 420Sailor said.

I reconnected the shift motor electrical connector & the motor won't move when using the dash switch. Suddenly now it won't move?

Stay tuned......

 

[rogueexplorer1]

Rotating the rear driveshaft allows the TC shift motor shaft to rotate to all positions, so no binding there.

Looking for wiring diagrams for the shift motor connector to test it. Can't find any bad fuses as of yet but haven't checked every single 1 of them. Don't think I need to unrelated fuses. Haven't tested any relays. TC has a large 20A fuse but I don't see a relay listed in the owners manual.

Trying to figure out what is the main power supply wire to the TC shift motor. My Haynes manual is not great for wiring diagrams.

 

[C420sailor]

I think you may have bigger problems. Forget the shift motor for now. Manually put the case in high range and test the truck in drive and reverse.

If it won’t move, or has delayed engagement, your problem likely lies upstream, in the tranny

 

[rogueexplorer1]

Pretty crazy I didn't think or this earlier!! Called the tranny place that said 100% it was only the transfer case that was bad & the tranny was fine, the guy suggested I check the tranny fluid. Low & behold, there was no reading on the dipstick. I put 2 qts in & it shifted fine! It still isn't showing on the dipstick. I didn't see any leak coming from the tranny but there was a lot of fluid in the TC when I removed it.

Only issue I'm having now is that there's a speed sensitive whining I'm hearing. Can't tell what it is. I'm gonna see if my buddy who has a lift can help me check it out. Hopefully it'll do the same thing on the lift & not under load.

 

[wollimann]

I didn't see any leak coming from the tranny but there was a lot of fluid in the TC when I removed it.

Did you change the TC input seal? It is possible that tranny fluid moved to the TC when seal is bad.
Got this two times, 1,5 liter too much oil in the TC, and the TC is getting very hot.

Whining could be caused by the TC differential,
have one spare TC that whines a little bit , but only in first and second gear.
Changed the little needle bearing and the bras bushing, didn't help, still a discreet whining.

 

[C420sailor]

Get that level correct

 

[rogueexplorer1]

Get that level correct

Tranny Fluid Level or TC fluid level? TC is on; just dripped out of the fill hole, Tranny; hard to read after you put fluid in but it’s right around the top of the hash marks area.

 

[rogueexplorer1]

Back on it after a week break to see my bro. Drove it about 6 miles; Drives & shifts fine in AUTO now that I added about 2.5 qts of ATF. As I drive I hear a bit of a whine that's speed sensitive, as mentioned before. Not sure where that's coming from or if its something I should worry about. As Wolliman said before, some/most TC's have some kind of a sound. Shifted it into 4HI & 4Low; with both settings, as I slow to a stop, I get a pretty good thud at around 5 mph. Never noticed that before, but it's there now. In 4Low it also shifts quickly into 2nd but normal into 3rd, which I think is normal?

All in all, it runs & drives pretty well, so I would declare this mostly a success! I'll see what happens as I put more miles on it.

 

[rogueexplorer1]

Also, just checked the trans dip stick & it's not showing fluid at all. Got another qt & will add & see if it shows after that. This will make 3.5 its added. I didn't drain the trans fluid & there was no leak from the rear trans output shaft seal that I could see when the TC came off. Maybe I should pull the TC fill plug & see if that fluid is way over full?

 

[C420sailor]

Yes I would check the TC level before adding more.

That said, that is awfully low. I hope that whine isn’t damage that was done to your transmission from the low level.

How are all the u-joints and CV on the front shaft? I like to rule out bangs and such from those.