Help, AWD, Tranfer case / front drive shaft question......

I have finally located the 'noise' under my 98 Exploder.

After a year of questions here, checks with my friendly transmission shop
(sadly now retired) and cash for nothing at my dealership...... I let it go
till it was so bad, it became obvious what the issue is.

Raise the car off the ground and rotate the front wheels, the noise is
coming from the front of the Transfer Case. There is a solid looking
UJ/spline slide assembly in line with the drive shaft. Its not a yoke, but
solid. This looks like it might be the equivalent of auto-locking hubs, but
on the shaft. Am I close?

I took off the rock shield and tried to remove the front drive shaft. Haynes
doesn't describe this model so I am unsure how to get it apart. I cannot get
the shaft out. Do I have to drop the front diff? I hope not.

Is the UJ/spline slide assembly at the front of the transfer case removable
and replaceable?
Any clues how to drop the front drive shaft.
Its a Borg Warner TC, but no idea which number describes.

All help appreciated.

David, Raleigh.

No Email Address wrote:
>I have finally located the 'noise' under my 98 Exploder.
>
>After a year of questions here, checks with my friendly transmission shop
>(sadly now retired) and cash for nothing at my dealership...... I let it go
>till it was so bad, it became obvious what the issue is.
>
>Raise the car off the ground and rotate the front wheels, the noise is
>coming from the front of the Transfer Case. There is a solid looking
>UJ/spline slide assembly in line with the drive shaft. Its not a yoke, but
>solid. This looks like it might be the equivalent of auto-locking hubs, but
>on the shaft. Am I close?
>
>I took off the rock shield and tried to remove the front drive shaft. Haynes
>doesn't describe this model so I am unsure how to get it apart. I cannot get
>the shaft out. Do I have to drop the front diff? I hope not.
>
>Is the UJ/spline slide assembly at the front of the transfer case removable
>and replaceable?
>Any clues how to drop the front drive shaft.
>Its a Borg Warner TC, but no idea which number describes.
>
>All help appreciated.
>
>David, Raleigh.

You are looking at the constant velocity joint on the rear of the driveshaft
where it mounts to the transfer case.. The AWD transfer case is a Borg
Warner 4403 I think. Below are the instructions from the manual for pulling
the front driveshaft. The bolts that hold the driveshaft to the transfer
case are not supposed to be reused. The constant velocity joint cannot be
rebuilt, you gotta go buy a new driveshft. Get a good hex head socket (Sears?
)to remove the bolts - they are tuff to get out

Torque the transfer case side bolts to 22 ft lbs., and the differential side
bolts to 11 to 15 ft lbs. Ignore #1 and #3 since you are installing a new
driveshaft


1 .Index-mark the front axle pinion flange to the front driveshaft.
2. Remove the transfer case skid plate.
3. Index-mark the transfer case pinion flange to the front driveshaft.
4. Remove and discard the front driveshaft CV joint-to-transfer case bolts
and washers.
5. Remove the front driveshaft-to-front axle bolts.
NOTE: Always disconnect the front driveshaft from the transfer case first.
Remove the front driveshaft.

NOTE: Install new front driveshaft CV joint-to-transfer case bolts and
washers and new front driveshaft-to-front axle bolts and straps. NOTE: Always
install the front driveshaft at the front axle first. Follow the removal
procedure in reverse order.


--
Message posted via CarKB.com
http://www.carkb.com/Uwe/Forums.aspx...lorer/200506/1

The reason I couldn't get it out was the CV joint (as you so correctly point
out) had dissembled itself internally and removed most of the spline from
the drive shaft - so THAT was the noise !!! The shaft wouldn't push back
into the CV and hence I could not get the front yokes off the diff. However
with a bit of cunning and your confirmation it came (in other words - I hit
it).

Usually when I dabble with cars its $30 (£17) worth of parts and two days of
labor. When I finally got this off it cost me half a day of labor and $530
(£300) for a replacement shaft!!!!! Can you believe that?

Thanks again.

David, Raleigh











"ross via CarKB.com" > wrote in message
...
> No Email Address wrote:
>>I have finally located the 'noise' under my 98 Exploder.
>>
>>After a year of questions here, checks with my friendly transmission shop
>>(sadly now retired) and cash for nothing at my dealership...... I let it
>>go
>>till it was so bad, it became obvious what the issue is.
>>
>>Raise the car off the ground and rotate the front wheels, the noise is
>>coming from the front of the Transfer Case. There is a solid looking
>>UJ/spline slide assembly in line with the drive shaft. Its not a yoke, but
>>solid. This looks like it might be the equivalent of auto-locking hubs,
>>but
>>on the shaft. Am I close?
>>
>>I took off the rock shield and tried to remove the front drive shaft.
>>Haynes
>>doesn't describe this model so I am unsure how to get it apart. I cannot
>>get
>>the shaft out. Do I have to drop the front diff? I hope not.
>>
>>Is the UJ/spline slide assembly at the front of the transfer case
>>removable
>>and replaceable?
>>Any clues how to drop the front drive shaft.
>>Its a Borg Warner TC, but no idea which number describes.
>>
>>All help appreciated.
>>
>>David, Raleigh.
>
> You are looking at the constant velocity joint on the rear of the
> driveshaft
> where it mounts to the transfer case.. The AWD transfer case is a Borg
> Warner 4403 I think. Below are the instructions from the manual for
> pulling
> the front driveshaft. The bolts that hold the driveshaft to the transfer
> case are not supposed to be reused. The constant velocity joint cannot be
> rebuilt, you gotta go buy a new driveshft. Get a good hex head socket
> (Sears?
> )to remove the bolts - they are tuff to get out
>
> Torque the transfer case side bolts to 22 ft lbs., and the differential
> side
> bolts to 11 to 15 ft lbs. Ignore #1 and #3 since you are installing a new
> driveshaft
>
>
> 1 .Index-mark the front axle pinion flange to the front driveshaft.
> 2. Remove the transfer case skid plate.
> 3. Index-mark the transfer case pinion flange to the front driveshaft.
> 4. Remove and discard the front driveshaft CV joint-to-transfer case bolts
> and washers.
> 5. Remove the front driveshaft-to-front axle bolts.
> NOTE: Always disconnect the front driveshaft from the transfer case first.
> Remove the front driveshaft.
>
> NOTE: Install new front driveshaft CV joint-to-transfer case bolts and
> washers and new front driveshaft-to-front axle bolts and straps. NOTE:
> Always
> install the front driveshaft at the front axle first. Follow the removal
> procedure in reverse order.
>
>
> --
> Message posted via CarKB.com
> http://www.carkb.com/Uwe/Forums.aspx...lorer/200506/1

No Email Address wrote:
>The reason I couldn't get it out was the CV joint (as you so correctly point
>out) had dissembled itself internally and removed most of the spline from
>the drive shaft - so THAT was the noise !!! The shaft wouldn't push back
>into the CV and hence I could not get the front yokes off the diff. However
>with a bit of cunning and your confirmation it came (in other words - I hit
>it).
>
>Usually when I dabble with cars its $30 (£17) worth of parts and two days of
>labor. When I finally got this off it cost me half a day of labor and $530
>(£300) for a replacement shaft!!!!! Can you believe that?
>
>Thanks again.
>
>David, Raleigh

Yes, the car makers have fairly competitive prices on the parts you can buy
in the aftermarket, but if it isn't available as an aftermarket part, then
the skys the limit.

I have found a junkyard in my area (Colorado) that has a pretty good
selection of late 90's Exploders. Really good if you need one of those
elctronic modules - more Ford suck your wallet dry parts.

Glad it finally worked out with that bigger hammer!


--
Message posted via CarKB.com
http://www.carkb.com/Uwe/Forums.aspx...lorer/200506/1