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Transfer Case Model 4405: Reassembly

  1. Before assembly, lubricate all parts with MERCON ATF. Drive in output bore bearing and install snap ring retainer. Install front output yoke oil seal.
  2. Assemble sun gear, thrust washer and thrust plate and press onto input shaft. See Figure . Press bearing onto input shaft and install external snap ring.
  3. Install front planet to sun gear and input shaft. See Fig 4 . Install internal snap ring to planetary carrier. Place large tanged snap ring in case and expand snap ring and install planetary carrier. Check installation by tapping on input shaft with wooden block to ensure snap ring is properly engaged.
  4. Install nylon wear pads onto shift fork. Ensure dots on pads are installed in fork holes. Install high-low shift fork and shift collar on shift shaft together into front planet.
  5. Inspect oil pump outside surfaces and bore for discoloration. Replace assembly if discolored. Install oil pump on rear output shaft with retaining arm of pump towards rear of case. Ensure pump turns freely. Prime pump through oil filter pick-up tube while turning output shaft. Output shaft must turn freely within oil pump. If binding occurs, re-align pump until it fully seats and rotates freely.
  6. Install output shaft and oil pump assembly in input shaft. Ensure splines of output shaft engage splines of high-low shift collar, and oil pump retainer and oil filter leg are in groove and notch of front case.
    NOTE: Driven sprocket must be installed with REAR mark facing toward rear cover.
  7. Install oil pan magnet in slot in front case. Install front output shaft into front case. Install thrust washer. Install chain, drive and driven sprocket as an assembly.
  8. Install tone wheel onto front output shaft. Ensure splines on tone wheel and output shaft properly engage. Install clutch pack assembly on rear output shaft. Ensure clutch splines properly engage.
  9. Install snap ring on output shaft in groove just above clutch pack. If snap ring will not install thrust washer inside clutch pack may not be properly installed.
  10. Install wave spring insulator washer and armature. Install apply cam onto rear output shaft. See Figure . Install 3 balls and coil housing. Install thrust bearing onto output shaft.
  11. If removed, drive front output shaft ball bearing into rear cover bore with appropriate bearing driver. If removed, install rear output shaft bearing into rear case bore. Ensure bearing is not crooked and install internal snap ring in case bore.
  12. Install electromagnetic clutch coil in rear case. Ensure wire is not pinched. Install coil washers and nuts. Tighten to 72-96 INCH lbs. (8-11 N.m.).
  13. Slide spring spacer and spring onto camshaft. Position first spring tang to left side of drive tang. Wind second spring tang back to right side of drive tang. Slide spring and spacer in as far as possible. Install helical cam onto camshaft with cam tang in between spring tangs. See Figure .
  14. Install pin on tang end of camshaft assembly in alignment hole in front case. Camshaft assembly tangs should point toward top of case and lightly touch high-low shift fork assembly. Install shift rail through high-low shift fork. Ensure shift rail is seated in case bore.
  15. Install speed sensors. Upper speed sensor has a longer lead. Install vibration damper (if equipped). Tighten to specification. See TORQUE SPECIFICATIONS  .
  16. Install upper tone wheel, speedometer gear and rear output seal. Coat transfer case mating surface with non-acid cure silicone rubber sealant.
    NOTE: If rear cover assembly does not seat properly, move rear cover up and down slightly to permit end of shift rail to enter shift rail hole in rear cover boss, or tap rear output shaft with a sharp blow using a rubber mallet in a direction away from front output shaft while pushing down on rear cover.
  17. Place transfer case shift shaft into 4H detent position. Align output shaft with bore. Align helical camshaft assembly with shift motor bore. Install rear case half and bolts. Tighten bolts to specification. See TORQUE SPECIFICATIONS  .
  18. Install shift shaft seal using appropriate seal installer. Rotate shift motor counterclockwise until shift motor is aligned with mounting holes. Align triangular shaft to align with mating groove on motor. Loosen shift motor support bracket.
  19. Apply non-acid cure silicone rubber sealant to shift motor mating surface. Install shift motor and retaining bolts and tighten support bracket bolts to specification. See TORQUE SPECIFICATIONS  .
  20. Reinstall wires into proper terminal cavities in transfer case harness connector. See Fig 1 . Route wiring harness close to motor to avoid damage to harness.
    Fig 1: Identifying Transfer Case Harness Connector Pins (Explorer)
    G96I04686Courtesy of FORD MOTOR CO.
  21. Install flange on front and rear output shaft. Install rubber seal, yoke washer and nut. Tighten nut to specification. Refer to the TORQUE SPECIFICATIONS  table. Refill the transfer case with 2.5 qts. (1.5L) of ATF (just below the fill plug). Install transfer case. Refer to REMOVAL & INSTALLATION  .
Fig 2: Exploded View Of Borg-Warner Model 1354 Electronic Shift Transfer Case (Ranger)
G94G39178Courtesy of FORD MOTOR CO.
Fig 3: Exploded View Of Borg-Warner Model 1354 Mechanical Shift Transfer Case (Ranger)
G94H39179Courtesy of FORD MOTOR CO.
Fig 4: Exploded View Of Borg-Warner Model 4405 Transfer Case (Explorer)
G96E04689Courtesy of FORD MOTOR CO.
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