QUESTION: Cost of new Transfer Case-96 XLT AWD

[96 Explorer XLT]

The "clunk" sound when I begin to accelerate turns out to be my transfer case. Obviously its not good.

The dealership has always done the work on my car and quoted me a new transfer case installed for $1900.00 with a 3 year warranty. I dont have the time or even want to try to attempt it but DAMN, thats not cheap considering its about about 1/2 of what its worth but its paid for and been a good vehicle so Im probably due for something major after 145k.

My thoughts were to source the case some place and then have the dealer install it. I did that with my AC and saved about $300

Whats the NP or BW # for a a 96 XLT AWD V8? That would help

Anyone know what the mechanic hours (dealer book) for install?

 

[chriswells78]

BW4405

I have one sitting on my garage floor right now but it has 152k on it, I'm sure you don't want it.


Look into having yours rebuilt by a tranny shop. It may be a cheaper option.

 

[MountaineerGreen]

Transfer case install is easy. Seriously, six bolts, two driveshafts, done. Save yourself come coin and DIY. Find a used case on www.car-parts.com, or PM kbabiak on here, you can save yourself come money.

 

[CDW6212R]

Ditto, do it yourself. BTW, they seem to be about $1100 new from big places, used units seem to go between $150 and $250. The mileage on used ones is getting higher, so that may not be a good option in 2-5 years.

The AWD units are BW4404 and BW4403, your AWD has to have a speedometer sensor, it should be a BW4404. The later BW4403 would not work, they have no speedometer sensor. I have a spare 97 model, I do not recall if it has a VSS sensor in it. Do you want me to check it, it should have about 74k miles on it? I sold a 99 model AWD that turned out to need a chain, they are hit and miss as used parts. Regards,

Chris, the BW4405 is the V6 4WD transfer case.

 

[chriswells78]

Whoops, type-0 I hate my laptop keyboard.

 

[CDW6212R]

I figured, I appreciate the Firefox spell checker.

 

[96 Explorer XLT]

Any thoughts having it rebuilt? Im going to guess around $800 to have it done.

As far as DIY, I agree but there is just 1 little thing. Im not a DIY person when it comes to vehicles.

I have a 77 Bronco Sport thats pretty mint and a 95 Porsche C4 993 and if I had the time and patience DIY, I wouldnt have any time.

If it isnt 1 car, its the other!!

I'll be the 1st to admit, Im a gas and oil person but **** about maintainence and keeping my vehicles in running order. I like to do my home work and between Rennlist, Classicbroncos.com, and Explorerforum.com--they are all great resources.

 

[96 Explorer XLT]

BW4405

I have one sitting on my garage floor right now but it has 152k on it, I'm sure you don't want it.


Look into having yours rebuilt by a tranny shop. It may be a cheaper option.

Appreciate the offer but think Im going to have it rebuilt.

 

[jimbo74]

glacier said he rebulids tcases and quoted me $700

 

[JoeMahma]

Just did this to my Mounty. Seriously, my son and I had it out and in in less than three hours and that was taking our time and running to the parts store for fluid. If you do decide to do it yourself and need any pointers please don't be afraid to PM me. Prices vary but I don't recall seeing any for under around 700.00. Good luck.

 

[rizzjc]

Yep, first major work I ever did on mine was the tcase, and I did it myself with no major drama. Got one for $200 from ped5stang here on the boards. Been in there for 30k-40k miles now.

 

[CDW6212R]

The AWD TC weighs about 75 pounds, ships at 80lbs.

 

[96 Explorer XLT]

Yep, first major work I ever did on mine was the tcase, and I did it myself with no major drama. Got one for $200 from ped5stang here on the boards. Been in there for 30k-40k miles now.

Im in the process of getting one from ped5stang for $250. Thats a fair price in my book.

Thanks for all the input.

 

[rizzjc]

Good deal. He's taken good care of me, so I hope it works out well for you. I still have my old case I want to take apart and fix, to have a backup if it goes again.

 

[96 Explorer XLT]

Received my transfer case and front drive shaft from ped5stang yesterday, had it installed today, and all is good.

Took a little spin in the snow and I didnt get a "Clunk, clunk, clunk" sound from the transfer case. Smooth as butter

I had a the rarer 4 bolt flange set up. My shop said I was lucky the original transfer case lasted me 145,000 miles because it was the "problematic" one. The "new" one they had installed said check out just fine, and was the new and improved transfer case.

 

[rizzjc]

Good deal!

 

[96 Explorer XLT]

My 6 month update on the transfer case replacement.

I developed a ratttle in the past month or so....it is a heat shield that is coming loose!!!

My rear dif. seal started leaking and thats actually being fixed as I speak and the shop is clamping down the heat shields as well.

At 147,000 miles, all is well with my XLT