BW4405 Transfer case - play in output shaft

[masospaghetti]

I removed my driveshaft for the first time last night to fix a leaking transfer case output shaft seal. Got the new one in, no problem...however, upon reassembly, I noticed that I can push the driveshaft up and down and the movement is within the transfer case, its not the slip joint or U-joint.

Is ANY play here acceptable? Does the TC need to be rebuilt (immediately)? Maybe this is why the seal failed to begin with?

Thanks all, 98 Explorer, 4.0 OHV, 5-speed manual, 200k miles.

 

[IZwack]

Play in the transfer case is not acceptable. Typically, the culprit is the casing itself - the bore holes elongate over time. Glacier's 4405 Rebuild Diary covers this problem:
http://www.explorerforum.com/forums/showthread.php?t=182071&p=1723769

 

[joecrna]

It shouldn't have any play at all. As mentioned, it is almost certainly the transfer "case" itself. This will likely end up being a TC replacement instead of a rebuild because of cost. If so, run the old one till it fails. What's the downside?

 

[drdoom]

Check the bearing in the case, it could be bad.

 

[IZwack]

Take care of it sooner rather than later because the new seal you install will still leak because the wobbling shaft is what's destroying the seal.

 

[masospaghetti]

Is that what Glacier is referring to, when talking about the Omega fixes?

"Lastly, the bearing on the output shaft tends to put a lot of sideways ovalling pressure on its bore and they fix this as well with a bore and sleeve replacement"

If so, run the old one till it fails. What's the downside?

Will I have warning before it completely fails? I don't want to get stranded somewhere (or cause more damage to my drivetrain). Currently, I get a "clunk" when I get on the gas hard but it's not that bad, just noticeable. I assume it's coming from the transfer case now that I found this.

 

[masospaghetti]

I got a quote from Transfer Case Express in Spartanburg, SC to fully rebuild the case, using the Omega case halves and 100% new internals (their words) for $645, w/o the shift motor. Sound reasonable?

 

[joecrna]

Thats what I meant by replacement. I don't think you could rebuild it or much less yourself. If everyhting inside is replaced or remanufactured. If they are using the Omega case, they are probably using the improved Omega shift fork too.

Doubt you would get much more warning before failure. I just don't consider a little stranding on the road that bad. It is a hassle though.

Read Glacier's thread. Then call TC Express and confirm what exactly you get. All of the good improved parts? Shipping charges? You will be able to make a better decision. TC's are like transmissions, not cheap. Like a transmission, there can be a big difference from one persons rebuild to another. What you really want is a remanufacture. It sounds like that might be what TC Express is offering.

 

[masospaghetti]

I called TC Express, and they confirmed they are using both Omega case halves, but not the shift fork. (he said they could add that if I wanted, but for extra cost and that it was overkill.) Gears are replaced as needed, the rest of the parts are new. Shipping is an extra $85 both ways.

I see Rockauto has overhaul kits from Timken that include a bunch of parts: http://www.rockauto.com/catalog/x,carcode,1304424,parttype,16049

Are there any other parts that I should replace for sure? Clutches, etc? Chain? I'm trying to get a feel for the parts cost, if it's worth me tackling this on my own. Based on Glacier's rebuild thread, it seemed doable.

 

[drdoom]

IMHO, the enhanced shift fork is worthwhile. SONNAX makes the upgraded shift fork roller kit, sells for about $16.00 USD, easy to install. Or talk to Brad at Omega, he can sell you a new upgraded fork for a great price. Case halves are pricey, but any competent machinist can do the same thing to your case half also. The 4405 transfer case is very easy to work on. The price you are getting from TCE sounds good, especially if that includes shipping and core return freight. As posted above, the cost of transfer case hard parts can add up quickly.

For a little more info, here is a link to some 4405 repair kits:
http://www.riversidegear.com/transfer-cases-and-parts/ford-transfer-case-parts/4405-borg---warner-transfer-case-explorer---mountaineer/repair-kits-assorted-kits-to-fit-your-needs-1.html