Transfer case 4405 whining/humming - Removal

[rydrew55]

Hello,
I just finished an engine swap with a long thread. I am moving this question to a new thread to preserve the swap thread as this is unrelated.

My 98 4.0l SOHC 4wd makes a substantial whining, humming noise at certain combinations of road speed and engine load. Like decelerating down an incline with a light gas pedal applied, or light steady acceleration with some momentum and a moderate gas pedal. Not real loud, but more than I would say is comfortable.

I have read several threads here. Some point to rear diff pinion and carrier bearings and others say transfer case shift fork.

Is there some way to pinpoint the problem?

Note: my 4w hi is OK, but no response when switching to 4w lo. Dash light stays on 4w hi. OK in normal 2w operation with no light on dash.

Also, there is a fair amount of play in the driveshaft.

Thanks

 

[my98nnj]

Being the 4 low isn't working, the x-fer case would be the first place to look.

 

[rydrew55]

Transfer case whining / humming

Would really appreciate any thoughts on how to determine if I need to buy a transfer case.
And assuming the no 4-low is the shift motor could it somehow make the whining happen too by only partially engaging.

Thanks

 

[rydrew55]

Transfer Case 4405

Well no responses here, but I read a lot of threads. I think it is safe to assume that I need a new transfer case. Salvage yard for $100 (was $150 like everywhere else, but there were a lot of them around so he will do it for $100 with a 30 day warantee). It's from a 99 (mine is a 98)

Also, it finally went in to 4-lo, but crap, now it won't come out. I'll remove the shift motor tonight and see what's up.

Question, the yards had both YL24-7A195-AA and XL24-7A195-CA in stock from various 99 and 00's. I thought I read that any 1998 through 2001 BW-4405 would be OK. My buddy also needs one for his 99 EB and it's the XL24....CA, not the YL24.....AA like my 98 XLT.

Why different #'s?

Dear Moderator-I know you pulled this from 911 as it was not a critical situation, but could you put it in the Trans/Tranfer Case section so I might get some hits. My truck is down and I need to buy the case in the morning. Thanks

 

[rydrew55]

moderator-moved thread

Never mind, I figured out how to move it.
Thanks

 

[rydrew55]

Transfer case back in auto

The tr case has gone back in auto and has quieted down to a mild hum. I decided to drive it a bit more to wring out any other issues from the mustang motor swap before doing any more work and spend more $/time. It really is running quite nice as is, but eventually I will get deeper into this issue (and a few more minor ones). If you are interested, you can check out the project on my other thread "engine swap 98 sohc".

I would still like to hear any comments here before I undertake the tc (no replies yet).

Is the shift motor fix the same on my 98? Most of the posts were for gen I.

Is there any way to diagnose the tr case without pulling it?

Question, the yards had both YL24-7A195-AA and XL24-7A195-CA in stock from various 99 and 00's. I thought I read that any 1998 through 2001 BW-4405 would be OK. My buddy also needs one for his 99 EB and it's the XL24....CA, not the YL24.....AA like my 98 XLT.

 

[rydrew55]

Please help

Well things got worse in a hurry. I have parked the truck until I can fix it.

Please, any help will be appreciated.

Symptoms;
High pitch whirring with gas applied. Varies with speed all gears.
Low pitch hum, almost a grinding, with no gas. Sort of alternates with above. (new)

I think I need a transfer case.
Will any 4405 work? Mine is YL24-7A195-AA. I have found others with lower milage but #'s are slightly different, like XL24-7A195-CA. Or others from an 03 like
2 Dr (Spt), ID 2L24-7A195-AA
2 Dr (Spt), ID 3L24-7A195-AA
4 Dr, Sport Trac, ID 2L24-7A195-AA
4 Dr, Sport Trac, ID 3L24-7A195-AA
2 Dr (Spt), ID 1L24-7A195-BD
2 Dr (Spt), ID 1L24-7A195-BE
2 Dr (Spt), ID 1L24-7A195-BH
2 Dr (Spt), ID 1L24-7A195-BJ
2 Dr (Spt), ID 1L24-7A195-BK
4 Dr, Sport Trac, ID 1L24-7A195-BD
4 Dr, Sport Trac, ID 1L24-7A195-BE
4 Dr, Sport Trac, ID 1L24-7A195-BH
4 Dr, Sport Trac, ID 1L24-7A195-BJ
4 Dr, Sport Trac, ID 1L24-7A195-BK
4 Dr, Sport Trac, ID 3L24-7A195-AB


Also, my old 93 with auto hubs used to get stuck in 4wd until I replaced them. This one does not have the hubs and works differently (auto). My question is with front wheels up in air, is it normal that the drive shaft spins when I spin the tires or is it stuck in 4th?

Thanks

 

[rydrew55]

Last cry for help Transfer case removal

Moved back to Stock 1995-2001 forum due to no replies in Transmission forum. Thanks
I could really use some help before I start....no replies yet.
I read dozens of threads but could not find all the answers.
Seems pretty straight forward, but I am sure there are some good tricks that members have discovered.

I found out that the "YL24-7A195-AA" is just the newer version of the "XL24-7A195-AA". Either should work, and I found the YL which is also in the truck.

I could not find any info on the other ones, so I was forced to get it rather than a newer one. It has 121k so I am taking a chance, but no choice without better info. It was only $125 with the shift motor intact so I won't loose too much (just time) if I have to get another one (99 day warantee).

So with that out of the way, on to the removal and some questions.

1. Do I need to remove the shift motor to get the tc out/in? The replacement has it still connected so it would save some time and effort "and" I could avoid cutting and splicing the ground wire.

2. Is there any way to test the replacement for shift fork, guide wear or bad clutches without splitting the tc? The yard painted the case and said the warantee is void if I open it up.

3. Does the big round damper need to come off?

4. I noticed when I got home that the mounting dowel is not really round. Sort of looks like someone coiled some heavy sheet steel, overlapping it, to make up some slop. Looks strange, but if so, it was pretty well done and I think it will be OK. The seam is straight and smooth. Was this a cluge fix?

These and any other suggestions (like the best way to support the tc without a trans jack) would be greatly appreciated.

I got tremendous support from this site doing the Mustang motor swap (>140 posts) but nothing here yet. I am pretty good once I know how, but my weakness is no previous experience on the explorer.

It's a 98 4.0L sohc XLT.

Thanks, and hope to hear from you soon.

 

[94EddieBauerRock]

I wish I could be of help. I have a similar problem in my explorer (a 94) and haven't gotten much response either. I think that since there are multiple possible causes for the whining/grinding noise it can be hard to diagnose them. It sounds like you have it narrowed down to the transfer case. Good luck!

 

[drdoom]

Working on a 4405 now

I just pulled the 4405 out of '97 XLT. It is "stuck" in 4LOW. It started out on the highway, under power, when I crested a hill and started to "coast", I had a high pitched grinding followed by complete disengagement. As in this bad boy wouldn't stop rolling even when shifted into PARK. I got it in 4LOW to get off the freeway. Was later able to get it back into AUTO, but same thing happened. Drained the fluid...full of white plastic fragments (formerly the shift fork guide bushings). Tomorrow I plan to split the case open, to see how bad it is. I would like to purchase a re-engineered/manufactured case, but funds are really tight, so I am hoping to just replace the range shift collar, shift fork, and pump filter. I know this won't address the root problem (wear in the case halves) but at 167K, I am making this call. YMMV