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The Borg Warner transfer case was introduced in and is used by Ford in Explorer and Mercury Mountaineer vehicles. When in the automatic mode, the transfer case can vary the torque between the front and rear drive shafts so the vehicle can drive at highway speeds in full time 4WD. The transfer case includes a viscous clutch that is normally applied at a minimum duty cycle which transfer most of the torque to the rear wheels. The viscous clutch is filled with a high viscosity fluid, which flows through slots in the plates.
The resistance to shear causes the plates to transmit torque at the needed ratio. The clutch is a non-repairable item. When the GEM detects that the front and rear drive shafts speeds are equal, it returns the clutch pack to minimum duty cycle. The driver can manually choose to operate the transfer case in 4X4 HI mode by using the dash mounted rotary switch. This 4x4LO mode should only be used in low speed situations or off-road conditions. To shift into 4x4LO, the brake must be applied, transmission in neutral and vehicle speed less than 3-MPH.
The transfer case clutch pack receives a pulse width modulated signal from the GEM module and through a solid-state clutch relay. This signal is grounded when the clutch is active and shows battery voltage when off. The A4WD indicator shows the mode chosen. When active, the indicator circuit is grounded. The GEM performs self diagnosis and sets trouble codes. Tire pressure and size can have a substantial effect on the inputs from the drive shaft speed sensors to the GEM.
Even a few psi difference in tire pressure or tread wear between the tires can set a trouble code. The difference in rolling circumference can be caused by tread wear or tire pressure differences.
The Borg Warner transfer case is known to suffer mechanical failure resulting in a loss of drive accompanied by a ratcheting noise coming from the transfer case during coast or deceleration or when in reverse. Prior to the failure, the transfer case likely made an occasional thump noise at a constant road speed of MPH. Replacing these items will NOT solve the problem.
The range hub is designed with helical cut gearing that stays in mesh under load, but moves out of mesh on coast due to the thrust loads generated by the helical design.
Adding power causes the gear to return to the correct position. However, the bottom of the teeth get damaged and the constant pressure on the fork causes it to degrade and burn.
The root cause of the problem is an offset in the centerline distance, which places the shift rail at an angle, allowing the range fork to move out of position. The transfer cases is made from magnesium and rebuilding shop can re-machine the case to correct this design flaw. If you see units with oblong holes in the cases where the shift rail rides.
It is cheaper and more efficient to buy a rebuilt unit that has been re-machined than to try and correct this problem yourself. Ford has programmed the GEM module to generate pinpoint tests to track down the electrical glitches. Unlike the cheaper Haynes and Chilton manuals that cover multiple year models, leaving the exact information you need to fix your car, these professional manuals cover your exact year, make, model. Plus, they contain full trouble code descriptions and troubleshooting instructions.
Pricing: Eautorepair. So you have to refer to the factory legends to learn the identification symbols and then refer back to circuit diagrams to find the splice and ground locations. However, Alldatadiy. If you need to dig into your doors, dash or console, Alldatadiy. Borg Warner transfer case. Find this article useful? Share it! Categories Borg Warner transfer case. Tags Borg Warner transfer case.
Prominent words transfer 4wd high indicator light 4wd high indicator light circuit 4wd low indicator light circuit borg warner borg warner borg warner transfer dash mounted rotary switch drive shaft speed sensors front and rear front and rear drive front and rear drive shafts front and rear wheels high indicator light circuit indicator light circuit indicator light circuit fault light circuit short to voltage using the dash mounted rotary warner warner transfer.
Transfer Case BW4405 Rebuild Kit, Drawing & Parts List
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BW 4405 Transfer Cases
FORD Transfer Cases