Transfer case swap or rebuild options

[Mbrooks420]

I have a 1996 with the 44-05 t case. Something is wrong with the inside of the case, either a stretched chain or slipping TOD clutch. I tend to think that its the clutch, but have never heard a chain skip. It makes a snapping/binding sound but seems to happen as the TOD engages at the higher torque settings.
I was wondering if these are worth rebuilding? I can get a chain for $100, anyone know about the TOD clutch? Also what about swaping in a transfer case from a newer Explorer without 2wd setting? I can get one from a 2000 with 63 miles for $500.

 

[Doug]

My 4405 went soon after i bought and i swapped it out for a BW 1354 manual shift t-case from a ranger and its one of the best things ive ever done to my truck imho.

 

[justin146]

I'm not sure exactly what you are talking about. Your truck should make noise when the clutch locks up. A rebuild at the dealership will probably be over $1k. I think mine was like $1200 when my clutch failed.

 

[Mbrooks420]

Well I'm sure I can rebuild it for WAY less. My truck never goes to the dealer for ANYTHING. My truck used to make little to no noise engaging the front axle. Now it does. I thought about the 1354 but like the all wheel drive since I drive in a lot of snow and ice.

 

[Mbrooks420]

Well I'm sure I can rebuild it for WAY less. My truck never goes to the dealer for ANYTHING. My truck used to make little to no noise engaging the front axle. Now it does. I thought about the 1354 but like the all wheel drive since I drive in a lot of snow and ice.

 

[Doug]

Everything ive read and heard on this board has said its not worhtwhile to rebuild the t-case, its cheaper/easier to get a new one.

 

[Mbrooks420]

That's what I figured. I imagine it's pretty chewed up in there.

 

[tenikiwon]

What options do they have to replacement if you don't want to go manual.

MBrooks --> What about your center console in you go with a manual T-case? or are you manual?

 

[Mbrooks420]

I have an auto t case now, but don't have a full legnth console, so I'd just have to Sawzall a hole in the floor. You can also get the 1354 in auto.

 

[Doug]

if you go with another automatic t-case it can be a 1354 electric shift, they will only work in a first gen the computer that controls the t-case is different in a 2nd gen.

 

[tenikiwon]

What are the options then for a 2nd GEN. I like my current system, but I think it needs some work or something.

 

[Doug]

95-97s has the 4405e and the 98-2001s has the 4405w or something like that.

 

[dogfriend]

Originally posted by Namitey
95-97s has the 4405e and the 98-2001s has the 4405w or something like that.

What are the actual differences between the 95-97 case and the 98-01 case?

I'm thinking that he might be able to use the 2000 case in place of his 96. The GEM controls the engagement of the transfer case clutch and the front axle. If he just swaps in the newer case but keeps the same GEM and front axle disconnect, it seems like it would work to me.

 

[Doug]

Originally posted by dogfriend
What are the actual differences between the 95-97 case and the 98-01 case?

I'm thinking that he might be able to use the 2000 case in place of his 96. The GEM controls the engagement of the transfer case clutch and the front axle. If he just swaps in the newer case but keeps the same GEM and front axle disconnect, it seems like it would work to me.

You cant swap them 95-96 had a different outputshaft than the 97+ though if you swapped the front driveshaft as well i would imagine a 98+ t-case would work.

 

[dogfriend]

If he can get a low mile 2000 case for relatively cheap, it might be worth it to get the front driveshaft too.

I know what you are talking about with the CV joint - mine has a CV joint at the front output, I forgot that the eariler ones didn't.

Any other obsticles to swapping in the 2000? He needs the driveshaft from 97 up. I would think that the length would be the same. The 95-96 electronics should work ok unless there is some other detail I'm missing here.

 

[Doug]

the electronics *should* work but being that the t-cases are electronically controlled it might not work. but i would imagine it would. as far as the driveshafts being the same length theyre the same. when i put the manual case in my 97 i took the drive shaft out of my wrecked 96.

 

[dogfriend]

mikefox posted the schematics for the 95-96 in this thread :
Dead Link Removed

If you look in my photo gallery, I posted the same schematics for 97. I'm assuming that the 2000 case will have the same connections.

I think you only have to worry about the speed sensors, the shift motor and the t-case clutch connections. I don't think that the t-case clutch will care whether a 2000 GEM controls it or a 96 GEM controls it because all the GEM does is modulate the current (PWM) going to the clutch. You need to keep the 96 GEM to control the front axle disconnect.