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School Me On Explorer Transfer Cases

AlexSport'00

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Year, Model & Trim Level
GONE: 2000 Explorer Sport
I had been trying for about 45 minutes trying to figure out which transfer
cases the Explorers used. I know the information is on here, but I guess I
can't figure out the right combination of search phrases to use to get the
t-case numbers and their years and their functions all used in the same
thread. Finally I found some of what I needed when I searched the "brown
wire mod". So here is all the info I found consolidated into one thread. This
will help someone in the future.

This has quotes from an Autozone article.

"There are three transfer cases used on the Ranger, Explorer and
Mountaineer. There are 2 versions of the Borg Warner 13-54 (mechanical
shift and electronic shift), a Borg Warner 44-05 (Control Trac) and an All
Wheel Drive (AWD) transfer case."

1st Gen '91-'94 Explorers:
"The Borg Warner 13-54, mechanical shift transfer case, is a 3-piece
aluminum part time unit. It transfers power from the transmission to the rear
axle and when actuated, also the front drive axle. The unit is lubricated by a
positive displacement oil pump that channels oil flow through drilled holes in
the rear output shaft. The pump turns with the rear output shaft and allows
towing of the vehicle at maximum legal road speeds for extended distances
without disconnecting the front and/or rear driveshaft.

The Borg Warner 13-54, electronic shift transfer case, transfers power from
the transmission to the rear axle and also the front drive axle, when
electronically actuated.

This system consists of a pushbutton control, an electronic control module,
an electric shift motor with an integral shift position sensor and a speed sensor.

The electric shift motor, mounted externally at the rear of the transfer case,
drives a rotary helical cam. The cam moves the 2WD-4WD shift fork and
4H-4L reduction shift fork to the selected vehicle drive position. The system
has no selectable Neutral (N) setting.

The manufacturer recommends that the Borg Warner 13-54 transfer case
equipped vehicles should not be operated in 4WD (whether HI or LOW) mode
on dry pavement. Severe driveline torsional wind-up will occur, possibly
damaging the drivetrain components.
"

2nd Gen '95-'01 4x4 (V6 only):
"The Borg Warner 44-05 transfer case operates in the same manner as the
13-54, except that it also houses a transfer case clutch. This clutch, which
is controlled by the Generic Control Module (GEM), enables the vehicle to be
driven in 4-wheel drive on dry pavement by cycling the clutch to compensate
for different front and rear driveshaft speeds (as in turning). The system has
a dealer installable Neutral (N) position mode."

I found that gijoecam's BWM write up to be extremely helpful on
understanding the different systems for the BW4405.
http://www.explorerforum.com/forums/showthread.php?t=149388

2nd Gen '95-'01 AWD (V8 only):
"The All Wheel Drive (AWD) transfer case is a 2-piece aluminum, chain driven,
viscous clutch type unit. The AWD transfer case is always active in 4-wheel
drive, thus producing a full-time engagement. The viscous clutch
automatically distributes power to both the front and rear wheels, depending
on need."

I am far from an expert on these topics, I just wanted to consolidate some
info for people, including myself. If you see anything that is clearly wrong,
please let me know. Mods, if this post seems completely incorrect beyond
repair, please just delete it.

Also, I have seen the Borg Warner 4404 mentioned multiple times in different
areas. If I could get a clarification on where that it used, that would be
awesome. Also, this page on TheRangerStation http://www.therangerstation.com/tech_library/TransferCases.html
contradicts multiple things that I just posted. If anyone can tell me what on
there is correct and what isn't, that'd be great. It has lists different years
than me.
 



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Generic Control Module (GEM) I want to know more about this. Where is it. Can it go bad? I feel like I am getting damage to my transfer case because of unwanted shifts between high and low 4 wheel drive.
 






The Gem module is located to the left of the stereo in 95-01 explorers
Yes they can go bad
Usually its the t case shift motor that fails though

The control trac t cases are problematic when they get older

The 1354e shift and 1354m manual shift can be installed in its place, but there are some tricks to know

This t case thread is from 2014, what do you need to know? I think we have you covered in the other 97 control trac thread........
 






The Gem module is located to the left of the stereo in 95-01 explorers
Yes they can go bad
Usually its the t case shift motor that fails though

The control trac t cases are problematic when they get older

The 1354e shift and 1354m manual shift can be installed in its place, but there are some tricks to know

This t case thread is from 2014, what do you need to know? I think we have you covered in the other 97 control trac thread........

Well this mechanic is about to take me to the cleaners. I just need my Explorer back and running. So. If I just put up with this guy and get it running, maybe I'll take it to you to put in a different transfer case. I just need to know my options. This guy is gunna start working on it tomorrow. And wants 1,300 bucks.
 






Well this mechanic is about to take me to the cleaners. I just need my Explorer back and running. So. If I just put up with this guy and get it running, maybe I'll take it to you to put in a different transfer case. I just need to know my options. This guy is gunna start working on it tomorrow. And wants 1,300 bucks.
If you don’t trust him, don’t let him work on it. Simple as that. Tow it elsewhere.
 






Hey guys! I had a happy ending to this issue. Basically the original SPEED SENSORS in the 95-97
have faulty programming.

THERE ARE ACTUALLY NEW SPEED SENSORS WITH UPDATED PROGRAMMING.

Never heard about this on this forum so who knows maybe this could help some other people out.



The Gem module is located to the left of the stereo in 95-01 explorers
Yes they can go bad
Usually its the t case shift motor that fails though

The control trac t cases are problematic when they get older

The 1354e shift and 1354m manual shift can be installed in its place, but there are some tricks to know

This t case thread is from 2014, what do you need to know? I think we have you covered in the other 97 control trac thread........
 






There is no “programming” at all in a speed sensor. It’s a generic Hall effect sensor.
 






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