IZwack
Moderator Emeritus
- Joined
- February 5, 2003
- Messages
- 21,675
- Reaction score
- 49
- City, State
- Germantown, MD
- Year, Model & Trim Level
- 1998 Ford Explorer
Hybridized 4405 T-case (97 and 98 parts) > stuck in 4hi
hey all,
my brother's 97 40 sohc eddie bauer's transfer case (BW-4405) was making a funny sound so we pulled it the other day and cracked it open.. the tcase sounded like the chain was slapping against the casing itself.. so we purchased a new chain.. however, we also found this thing cracked in half:
one of the friction plate's friction material also disintegrated upon removal.
so we had a few parts to replace. luckily, a long time ago, i switched to a manual BW 1354 so i no longer needed my electric shift 4405 and its been sitting in the shed since then. of course, the easy thing would be to swap my 4405 (from my 98 X) to his 97 X. Problem is, in 98, the 4405 model had a few changes compared to the 97 and below models. Among other things, unlike the 97 4405, the 98 4405 has no speed sensor at the rear output shaft - so swapping that into the 97 would mean a dead speedometer (which is what happened when we tried it). so the only other option was to rebuild the 97 4405 using some of the 98's parts.
well so i did the rebuild - replacing that cracked gear pictured above with the gear from the 98 4405, and also the friction plates set on the 97 4405 were replaced with the set from the 98. but now it seems that the tcase is stuck in 4-hi. I dont think the electromagnet is being powered up so thats not the problem, but rather the friction plates are being engaged prematurely (when they shouldnt be). here is a shot of the two different friction plates set:
im thinking that the friction plates, or something in the entire clutch system is thicker than the original - causing the entire clutch pack to engage the front output shaft. anyone know whether or not the 98's 4405 friction plate set is thicker than the previous years? or any other part in the front engagement system?
oh and also, anyone know what the torque spec is on the rear flange's nut?
hey all,
my brother's 97 40 sohc eddie bauer's transfer case (BW-4405) was making a funny sound so we pulled it the other day and cracked it open.. the tcase sounded like the chain was slapping against the casing itself.. so we purchased a new chain.. however, we also found this thing cracked in half:
[
one of the friction plate's friction material also disintegrated upon removal.
so we had a few parts to replace. luckily, a long time ago, i switched to a manual BW 1354 so i no longer needed my electric shift 4405 and its been sitting in the shed since then. of course, the easy thing would be to swap my 4405 (from my 98 X) to his 97 X. Problem is, in 98, the 4405 model had a few changes compared to the 97 and below models. Among other things, unlike the 97 4405, the 98 4405 has no speed sensor at the rear output shaft - so swapping that into the 97 would mean a dead speedometer (which is what happened when we tried it). so the only other option was to rebuild the 97 4405 using some of the 98's parts.
well so i did the rebuild - replacing that cracked gear pictured above with the gear from the 98 4405, and also the friction plates set on the 97 4405 were replaced with the set from the 98. but now it seems that the tcase is stuck in 4-hi. I dont think the electromagnet is being powered up so thats not the problem, but rather the friction plates are being engaged prematurely (when they shouldnt be). here is a shot of the two different friction plates set:
im thinking that the friction plates, or something in the entire clutch system is thicker than the original - causing the entire clutch pack to engage the front output shaft. anyone know whether or not the 98's 4405 friction plate set is thicker than the previous years? or any other part in the front engagement system?
oh and also, anyone know what the torque spec is on the rear flange's nut?