1998 Mercury Mountaineer's Transfer case:
In July of 2003 I decided to tear into my 1998 Mercury Mountaineer's Transfer case. The truck would have a loud clunking or banging noise when I would accelerate from a stop. The problem started gradually, but over time with towing my sleds the banging got more and more often. It got to the point where just about 1/4 throttle from a stop resulted in the problem. I checked the drive shafts and the u-joints. I found that the front drive shaft was bad. It has a non servicable CV joint on the end of the drive shaft which bolts up to the transfer case. It was trashed. I thought for sure this was the problem. Cost about $220 from a dealership for the part and I easily replaced it myself. Well, I took it for a test drive and the clanking continued. This did fix a major vibration problem I had while accelerating and while crusing between 60+ I had a bad vibration which was also corrected with the new driveshaft. But the violent clanking continued. I decided to take it to a dealer since I no longer have my lift at home and they told me it was the transfer case. They wanted $1750 to install a rebuild. Knowing that they usually suck you dry and being familiar with pulling things apart and reassembling them (see my other pages below) I decided to dig into the transfer case myself. Here are some pictures as well as schematics for the Borg-Warner 4404 (BW4404 for short).
BW4404 exploded view:
Here is the bearing portion of the rebuild kit I got from Drivetrain Specialties! The kit also included all new seals. These guys are great. Their number is 1-800-216-1632. The rebuild kit cost $120 and the chain cost $106. Not bad. $250 with shipping was all I needed.
These are pictures of the rear section of the transfer case after I cleaned it up. The arrow points to a spring clip which clips into a groove in the bearing which is pressed on the output shaft. This keeps the bearing in place in the rear portion of the housing. Took me a while to figure it out.
The third picture has an arrow which shows the part that is clamped in place with the spring clip. That is a bitch to remove, but I assume the correct tool would help.
Here I am 1/2 way done reassembling the transfer case. The original chain was completely loose. I saw evidence of the chain rubbing on the inside of the transfer case. I assume when it skipped a tooth. All of the sprockets and gears looked good so I didn't bother replacing them.
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