Transfer Gearbox Output Shaft failure

[HenriS]

Hi guys
My Explorer has had, to my mind, an unusual failure. The spline shaft which drives the rear prop shaft in the transfer case has excessive wear causing a "clunking" during up changes and sudden acceleration at speed.
I took the vehicle to Transmission Specialists as I have breakdown insurance. Their report to the insurance guys was "Normal wear and tear". I must add that the vehicle only has 75k miles. The local agents have to order the replacement components from the US as there are none here in South Africa. Not that there are few of these Explorers around here!
Have there been any such failures that you guys know of? The insurance guys now are refusing to pay thus I am on a mission to prove that such components do not fail this early in a vehicle's life. These should last the life of the vehicle. I also cannot pick trhis subject up on the bulletin board.
Thanks a lot
Henri

 

[Robert]

I would think that the only way it could be considered normal wear and tear would be if replacing it were part of routine maintenance. Since it is not listed in my '97 Ford Service Guide, I would guess that it is not normal wear and tear. Incidentally, I have almost 86K on my '97 and it hasn't worn out yet. Another example of why I can't stand extended warranty companies. They will look for any excuse they can find to deny a valid claim. I ran into that with Warranty Gold. You might be better off contacting Ford Customer Care and asking them if the part is considered normal wear and tear. Also contact a few other Ford dealership service departments and ask them. If you can get statements from several people at various Ford locations, you might be able to sway your insurance companies oppinion. Does your insurance company offer you the chance to take a denied claim to arbitration? I believe mine does. It is supposed to go to some board that is supposedly impartial for consideration. Their decision is supposed to stand though. Check your insurance documents to find out.

 

[HenriS]

Transfere Case Output Shaft Failure

Thanks Robert, my sentiments exactly! My plans are the following:
1) Use this web site as proof (I have printed a few pages of discussions) and obviously your and hopefully more replies.
2) Ford South Africa has appointed Gearmax (where my vehicle was assessed) as their accredited repairs supplier and accordingly are pushing the problem back to them. I have a meeting set up with their Managing Director to endevour to obtain mere statistics as you say, "how many of these t/cases have you found with the same problem in the history of Gearmax's existance?"
3) I have rallied some support from the Ford agent Parts Managers (probably to the disgust of FMC South Africa).
Failing all of this resounding evidence, arbitration will be the next move.

Thanx for your help !

 

[BUCHVILLEMAN]

I have a BW 13-54 manual shift out of an early model explorer. my 1995 came with the 44-05 which is what i assume you have. The 44-05 failed me. The front output shaft was stripped, im not sure of the technical jargon but the chain would skip when torque was applied. i was quoted $700 for a full rebuild, $850 for a used unit, and $1100 for a new unit (i might be off as i knew i wasnt going to get it when the guy was talking to me.) I have always heard great things about Borg Warner products until i read "top ten things we hate" in a Off Road magazine last year and they had "any product by borg warner" listed. i disagree based on the early model explorers and f-150s success. i also am in love with my new t-case.

good luck