bigtooper
New Member
- Joined
- November 4, 2009
- Messages
- 4
- Reaction score
- 0
- City, State
- eugene oregon
- Year, Model & Trim Level
- 98 explorer xlt
98 Explorer 4405-10 tcase. Tcase started engaging front axle randomly and flashing the tcase lights on the dash. Took to local repair shop. They said #1 The rear output seal was leaking and the bearing had spun in the case. #2 When the rear case half had failed usually the pump arm has eaten into the front case half and it would need to be replaced as well. #3 There were a couple random codes which they cleared. Quoted me $1400 to repair. I had them drain and fill with fresh fluid for now.
That was August. Since then the tcase has only done this a couple time and no lights on dash. So I bought a Haynes manual (which was no help) to study up on doing the repair myself. Then I found this site!! Found a thread with nice pics and decided to go for it.
Removed tcase from Explorer. Removed rear output flange. Couldn't figure out how to remove range selector motor. Split case half's, wiggled and giggled until they came apart. Chain, front drive sprocket, shift fork and other small pieces all fell out. No problem.
I found nothing wrong with the rear case half. Front half notched where pump arm rubs. A couple of the clutch disks had friction material coming off. I think this was the cause of the intermittent engagement problem. As the material floated around it would "stack up" between the other plates a cause a clearance problem. And that wavy spring on the on the rear out put shaft was broken.
Since I work in a machine shop I"m going to install a steel pin in the front case half for the pump arm to ride on and order the clutches and spring from Ford. My daughters boyfriend gets a huge employee discount!
All that said. How do you get the range motor off the case? I tried prying up on it but it doesn't budge. I marked the cover and removed it to see inside no help there either. The motor swings around on the shaft until it hits the case but does not come off. Any help would be appreciated.
That was August. Since then the tcase has only done this a couple time and no lights on dash. So I bought a Haynes manual (which was no help) to study up on doing the repair myself. Then I found this site!! Found a thread with nice pics and decided to go for it.
Removed tcase from Explorer. Removed rear output flange. Couldn't figure out how to remove range selector motor. Split case half's, wiggled and giggled until they came apart. Chain, front drive sprocket, shift fork and other small pieces all fell out. No problem.
I found nothing wrong with the rear case half. Front half notched where pump arm rubs. A couple of the clutch disks had friction material coming off. I think this was the cause of the intermittent engagement problem. As the material floated around it would "stack up" between the other plates a cause a clearance problem. And that wavy spring on the on the rear out put shaft was broken.
Since I work in a machine shop I"m going to install a steel pin in the front case half for the pump arm to ride on and order the clutches and spring from Ford. My daughters boyfriend gets a huge employee discount!
All that said. How do you get the range motor off the case? I tried prying up on it but it doesn't budge. I marked the cover and removed it to see inside no help there either. The motor swings around on the shaft until it hits the case but does not come off. Any help would be appreciated.
