M50D grind coasting and no reverse

[KPT]

So I lost reverse and got an awful whining/grinding while coasting in gear. Both of these issues started at the same time. I haven't taken it apart yet but wondering what to look for. Would a reverse idler cause a whining while coasting in forward gears?

 

[97FordSport]

I am having the same grinding coast problem, is this a transfer case problem? I am currently searching the forums for this problem and this is the first post I have found, if someone can help me find more information or the correct term of what is happening so i can search it.

Thank you

 

[KPT]

My grind while coasting may be the transfer case. I've noticed the rear t-case seal leaks and if I push up on the driveshaft where it connects to the output shaft, the rear moves up and down significantly more than the front.

 

[gijoecam]

The grind/coast/no reverse issue is a common problem. The shift rail bores get oblonged, the shift fork fails to hold the planetary gears in position, and on deceleration, the gears grind. Run a search and you'll find plenty of answers.

 

[KPT]

Are these bores part of the case? I'm not finding anything searching.

 

[KPT]

Nevermind, I thought you were talking about the tranny, not the t-case.

 

[gijoecam]

Oh, sorry for the confusion... I may not have been clear.... Yes, I was referring to the t-case. It's a common problem with the Borg-Warner 44-05 t-case.

Now, that being said, I'm second-guessing myself... you have a manual transmission and 4 wheel drive on a '95? Which model transfer case do you have? I know they did some weird stuff for the 95 model year, that's why I ask.

 

[KPT]

Yes, manual tranny and 4x4. I am almost sure it is the 4405. The explorer is 2 1/2 hours away from me though so I can't check and I am stuck driving a Heep for now.

It is the control trac with the 2wd/4 auto/ 4 low switch. I've done the brown wire mod to get 2 low and 4 high so it pretty much has to be a 4405.

 

[colindo94]

This appears to be the same problem in a 1992 Explorer Sport, with the M50D 5spd tranny and the Borg Warner 13-54 manual t-case, that my brother is looking into, we figured it was the tranny?? is this also common on the 13-54 t-case as well??? if so how much do these run for rebuilt?

 

[Tbars4]

now i'm interested...i have a 95 xl ranger also and wierd describes it...everytime i go to get something looked at they claim that doesn't show up for a 95...transition year i guess, but i have a grinding noise at times with the clutch in but i beleive it to be an idler gear?

 

[97FordSport]

I am having the same grinding coast problem, is this a transfer case problem? I am currently searching the forums for this problem and this is the first post I have found, if someone can help me find more information or the correct term of what is happening so i can search it.

Thank you

Replaced my transfer case with a junk yard case. Fixed the problems I was having. the 44-05 are junk.

 

[97FordSport]

Replaced my transfer case with a junk yard case. Fixed the problems I was having. the 44-05 are junk.

Well 15K miles later and my junk yard case is doing the same coast grinding. So I guess I will be putting in another crappy 4405 case. yah!!!

 

[KPT]

Uh rebuild it and make it better than stock...

And random coincidence, I had to pull my tranny today and you happened to bump my old thread.

 

[gijoecam]

Well 15K miles later and my junk yard case is doing the same coast grinding. So I guess I will be putting in another crappy 4405 case. yah!!!

Here's a novel idea: Why not fix the problem right? In other words, get a set of case halves from Omega Machine with the re-bushed shift rail bores, and never have to deal with the issue again?

And if 44-05s are such junk, why do you keep replacing them? Why not replace it with a 13-54 manual case, or a heavy-duty one from an F-150 or Expedition?

If they're such junk, why do I have 172,000 miles on mine with nary an issue? Guess mine's just a fluke, huh?

 

[97FordSport]

Here's a novel idea: Why not fix the problem right? In other words, get a set of case halves from Omega Machine with the re-bushed shift rail bores, and never have to deal with the issue again?

And if 44-05s are such junk, why do you keep replacing them? Why not replace it with a 13-54 manual case, or a heavy-duty one from an F-150 or Expedition?

If they're such junk, why do I have 172,000 miles on mine with nary an issue? Guess mine's just a fluke, huh?

Well I was thinking it was a fluke the first time. but having it go out again seems pretty crazy!! Don't you think.

If they BW4405 where a good TC why would you have to modify to get it to work properly.

I don't quite understand why you are taking this so personally its like you built the BW4405 or something.

In all honesty I figured the last TC would last me till I dragged this truck into the junk yard. But I guess not.:roll:

 

[KPT]

Well I was thinking it was a fluke the first time. but having it go out again seems pretty crazy!! Don't you think.

If they BW4405 where a good TC why would you have to modify to get it to work properly.

I don't quite understand why you are taking this so personally its like you built the BW4405 or something.

In all honesty I figured the last TC would last me till I dragged this truck into the junk yard. But I guess not.:roll:

He is not taking it personally. You are throwing good money after bad. All 4405s will have the shift rail bore issue. I can not understand why anyone would go buy a junkyard 4405. They all likely have already worn the shift rail bores to some extent.

Do it right and rebuild one. Its easy.

 

[97FordSport]

He is not taking it personally. You are throwing good money after bad. All 4405s will have the shift rail bore issue. I can not understand why anyone would go buy a junkyard 4405. They all likely have already worn the shift rail bores to some extent.

Do it right and rebuild one. Its easy.

How many miles should you expect out of a 4405 transfer case? What is the cost of the omega housing.

I guess I didn't realize that all the 4405 cases are destine to fail. Figured it was just a percentage.

I got a case of ebay that has only 5,000 miles. Do I really need to rebuilt this one. I figure this truck has less than 10K miles left on it. Same reason why I fugred that last TC would last me.

 

[KPT]

You should be fine if it only has 5K.

Mine had the grinding around 150K. I think 100-150K is all they last typically.

 

[97FordSport]

Well I screwed up. the case I bought was (99 00 Explorer Mountaineer Transfer Case Warner 4405)

I totally forgot that the 97 has a the speed sensor in the TC

So does any one have any ideas on getting this to work. can I swap some parts around to get it to work.

when it comes in I will drop my old TC and start comparing

:roll:

 

[gijoecam]

Well I was thinking it was a fluke the first time. but having it go out again seems pretty crazy!! Don't you think.

If they BW4405 where a good TC why would you have to modify to get it to work properly.

I don't quite understand why you are taking this so personally its like you built the BW4405 or something.

In all honesty I figured the last TC would last me till I dragged this truck into the junk yard. But I guess not.:roll:

It's a relatively simple design with very few failure points, but the shift rail bore issue is what it's notorious for. They're all destined to fail there sooner or later. It's that t-case's achillies' heel. Also, for every one of those you read about, there are tens (if not hundreds) of thousands of them still rolling down the road every day with nary a hint of an issue. My guess is that the manual trans accelerates the wear on the shift rail bore due to the constant loading/overrunning of the drivetrain typically seen in a manual trans vehicle.

Well I screwed up. the case I bought was (99 00 Explorer Mountaineer Transfer Case Warner 4405)

I totally forgot that the 97 has a the speed sensor in the TC

So does any one have any ideas on getting this to work. can I swap some parts around to get it to work.

when it comes in I will drop my old TC and start comparing

:roll:

The only direct plug-n-play case will be out of another 97. The 95-96 will have the speed sensor, but will have a u-joint flange front output. The 98-01 will have the proper flange, but not the speed sensor (as you discovered). Someone rebuilt one several years ago (IZWack comes to mind??) with a hybrid setup... used the old rear case half from a 97 case and the front half and guts from a 98-01. It worked, but the issue with the shift rail bore on the back half from the 97 will still be there.

You need new or rebuilt case, plain and simple, possibly a shift rail depending on how the ends look, and the pads that go on the end of the shift fork. Check the planetary gears closely for any signs of wear too... I've seen some pics here of some pretty gnarly ones.

Good luck!