Transfer case repair - why does it happen?

[quietone]

I have a 97 Explorer XL and have had problems with the transfer case (Borg Warner F77). I have had it rebuilt twice since June 2001 and am now going to do it myself. I am trying to figure out what causes it to go out in the first place.

Symptoms: When decelerating or going down a hill, it sounds like the transfer case / tranny just starts to race - like it came out of gear. Engine RPM's stay the same. Tranny appears OK. It will reengage when I accelerate or when I shift to neutral, stop, and restart.

First rebuild was broken shift fork, pump, bearings, gears, and shaft. Second was pretty much the same.

I have checked the shift motor and its clean, operates freely, and looks good (like new). The only thing I have found this time is a broken shifting fork.

What could be some of the causes of the shift fork breaking? I suspect the travel distance of the motor not being adjusted right but wonder if it could be something outside of the transfer case itself. Any help or suggestions will be a great help.

 

[mrboyle]

I'm not sure why this happens either, but we have a '97 in the shop right now with the same problems awaiting a NEW t-case. Once I swap out the old case I plan on doing a little investigating to see if I can figure out what is causing the problem. I'll do a write-up and send it to Rick if I come up with any answers.

 

[machman]

I'm taking my 97 down to have them look at it but based on everyting I've read and heard, it sounds like a bad design and I'll need a new (re-designed) one. Makes you wonder why Ford had to re-design it.

 

[Jason_25]

Is this specific problem isolated to the 97 model year?

 

[mbeckwit]

Hi, Mine is in the shop right now. I had the transfer case rebuilt in Nov. and within a week out of the shop the same decelerating whining. I took it back and they took it apart and said all looked well. I knew it would be back. So, it happened last weekend, and now it is back in, I just spoke to them, and the same thing, gears stripped,etc. The first bill was $2000, I don't know what this one is yet. There must be a secret warranty on this problem with ford. Has anyone checked?

 

[BUCHVILLEMAN]

i said to hell with mine and put in a manual shift bw1354. works better than the 44-05 that my 1995 came with...by far!