Transfer case went out on my 97 4.0 explorer :/ looking to replace asap

[Zach Coutts]

Looking to replace this transfer case myself with a buddy of mine. I got the 4405 I believe. Looking to completely replace and/ or upgrade it. Any tips or advice anyone can throw at me would be greatly appreciated!

 

[Zach Coutts]

Edit: Looking to seriously improve this rigs 4x4 capability. Anything I can do while I'm already down there with my driveshaft and such for improvement?

 

[RangerX]

Swapping out the tcase should be fairly straightforward, but as I’m not so familiar with gen2s, my advice is only worth 2 cents.

4x4 capability would be improved by things like adding a limited slip or a locker to the axles, better/bigger tires, lifting for more clearance, etc.
there may be some things in this thread that would interest you: List of Useful Threads - Modified 2nd Gen Forum's Best Threads

Welcome to the forum!

 

[ThreeJs]

I went through this June last year. Be aware of your speed sensor location. 1995-97 the sensor is in the transfer case. Later models are in the rear diff. Later model t/c will require swapping case halves.

my thread.
96 EB 4r55e,4.0 OHV. Loss of transmission gears

 

[410Fortune]

@ThreeJs nailed it

Yes since it is a 97 DO NOT throw away or trade in your t case as a core!
chances are you will need the back half if it with the speed sensor.
Finding a good 4405 t case is not too hard.
Finding a good 4405 t case for a 96-97 is extremely rare
So using the back half of your existing 97 case on a known good low mile 4405 is usually the route we take

OR

You can consider a control trac delete........ and swap to a 1354e or 1354m t case

That is what I would do, the control trac t cases are problematic when compared to the non control trac offerings

 

[Zach Coutts]

@ThreeJs
The wheel speed sensor? Have that on top of my rear diff. Would that mean I wouldn't have to swap halves?

 

[ThreeJs]

VSS = Vehicle Speed Sensor. Located on the rear of the transfer case. Look around the shift motor. Just in front of the output flange. A pic to show location.

 

[410Fortune]

not wheel speed sensor no, this is the VSS we are talking about (vehicle speed sensor)
in 97 there are two VSS one in the tailhousing of the transfer case
and one in the rear diff.

The ABS uses the one in the rear diff
The engines computer uses the one in the transfer case

The VSS in the transfer case was from 83-97
You must keep it for your PCM to be happy.

 

[RickOTR]

Why not just rebuild the one you have. Mine gave up the ghost over a year ago and I rebuilt it myself with regular tools. Installed all the updated parts from Omega Machine along with the updated shift fork. Problem solved for around $600.

https://sales.omegamachine.com/SearchResults.asp?Search=BW4405

The Borg Warner 4405 Transfer Case Rebuild Diary

 

[Zach Coutts]

@410Fortune
Kind of frigged myself over now, got the new remanufactured unit and it does indeed have the VSS spot but I'm assuming just doesn't have it inside the transfer case? Is that a thing, or could it be the sensor itself? Thought I was all good when it went together piece for piece and was identical from the outside, soon to find out the VSS doesn't work and my PCM is pissed off. Learning the process of my 1997 and not having too much fun so far. Any help would be greatly appreciated. Thanks.

 

[410Fortune]

if the new t case has an open hole for the sensor you need to put your old 97 speed sensor in the hole?
You said the new case has a spot for it?

What are we missing?

let me guess the new case was never drilled for the speed sensor?
Do you still have your old 97 case?

 

[Zach Coutts]

@410Fortune
Yes, the new case has a spot for the speed sensor. Plugged the old speed sensor (VSS) right in and nothing. No speedometer on its first drive out. Drove great for a couple of minutes then my PCM started to react badly which in turn made it much worse to drive. I do have my old case just in case something like this were to happen.
I'm ready to swap halves today, as I don't know what else to do.
Do you happen to have any experience with this or this manufacturer?
Link below for where I purchased my new BW4405.

BW4405 Transfer Case for Sale, Remanufactured Rebuilt

BW4405 transfer case sale. This is not just a rebuilt BW4405, this is a Borg Warner OEM replacement that has been completely remanufactured with upgraded parts.

spprecision.com

This is it with everything put together besides the VSS (can see the spot in this picture)

 

[RickOTR]

Sounds like they did not install the speedometer gear inside the case.
BW4405 TRANSFER CASE SPEEDOMETER GEAR 7T FITS '95+ FORD MAZDA (4405-110-001)

Should be able to install one by removing the rear output yoke as it just slips over the output shaft splines.

 

[Zach Coutts]

@RickOTR
Indeed they did not install one. Just swapped halves with my old one and am now installing though. Hope for the best!

 

[410Fortune]

I would NOT BE HAPPY
no drive gear inside the case??????
WTF are they doing

Seriously big huge hole in the rear part of the case and no drive gear = slap that mechanic

Sounds like you have it sorted out!!

 

[Zach Coutts]

@410Fortune
Safe to say I won't be going back to them for anything. Everything is much better now, compared to before.
..Have a sort of crunching sound that happens every once in a while on the road is the only issue now.. Mainly on turns. First thought would be a bad u-joint but I have a bad feeling it's from the T-case. Haven't been able to find anything directly pointing towards this problem what so ever.
Have any ideas for what might be holding me back this time?
Again, huge thanks for all the help I've received on this forum.

 

[410Fortune]

remove front d shaft see if noise goes away