The Borg Warner 4406 rebuild parts

[Turdle]

Well, the wife says it is ok to rebuild B's transfer case.
Since this involves disabling the truck I want to re gut it. The problem is I have no clue what is inside, and what to look for once in there.

So, besides the oil pump securing mod Tim posted, and new pump, what should I have on hand for this. I have seen some "rebuild kits" but they do not show magnetic clutches. However I do see them listed on ebay. I know the chain needs to be removed to check it, so, let's assume it is stretched.

Problems--slight grindy sound since install. Noisier than my previous 4406 ( although I admit that was a louder truck), some weird vibration, clunking-binding on turns in 4wd which I didn't experience with my earlier mentioned truck ( which had a locker i might add).

Fluid gets black early.

4wd has a mind of it's own and will just "slip out". I can shift to 2wd and back to 4wd but after bind -clunk pop during a turn it will "loose" 4wd .


If anyone can lend a hand I would appreciate it. I have the physical help here, I just need a good parts list please.

Thanks!


P.S.
I am also Double cardon challenged. I would like to rebuild that also but seem to be using incorrect search terms--:scratch:

 

[vroomzoomboom]

both cases i have "helped" with jon, all that was really needed was bearings and seals. you have that sleeve i mentioned, and a new pump.
i will also add that the case we did for don, the first time he tried to take it out of 4 low, it grinned on him as well, and everything was mint inside.
also, there is no gasket for the two haves. buddy used a sealer called "the right stuff" that comes in a smaller tube like you would see to silicone your bathtub with

 

[CDW6212R]

Hello guys, I just got back here, missed you all.

I would also like to know how to rebuild the BW4406, my 98 Navigator version may or may not be the advertised 59k miles.

Jon, is yours the TOD unit, or the manual version?

 

[Turdle]

Don, mine is the manual shift version.