hi. im rebuilding 1997 explorer transfer case . i believe its a c trak type. it has a 4.0 SOHC motor with 5R55E trans. tag on the T.C. 4405-08

[Ricksandoval]

rebuilding 1997 explorer transfer case . i believe its a c trak type. it has a 4.0 SOHC motor with 5R55E trans. tag on the T.C. H0561 109048 4405-08 F77A-GA. I need some help.

 

[Louisrgr]

What a coincidence I’m doing the same thing just pulled my transfer case five minutes ago from two feet of snow. Here’s a thread:

How to: - The Borg Warner 4405 Transfer Case Rebuild Diary

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...

www.explorerforum.com

that should help you, I have a little bit of power out to the front wheels from my transfer case then once the rear wheels start to slip I get nothing in the front. No pops or grinding either. Looks like someone has worked on mine before as well. Likely since its unique to its year with different drive shafts and sensors. Hopefully someone has an answer as to where I should look before I start teardown

 

[drdoom]

Make sure you have bushings machined into the case halves, that is key to reliability. Replace the shift fork pads. Also get the SONNAX shift fork roller upgrade. Check the range collar.
Those are just the basic necessities, obviously you can replace a lot more.
They are pretty simple internally, just stay organized.