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Center Manager
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4WD
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select
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8 6 4 2
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A brake-pedal-position sensor the 4411 design, propshaft speed circuit. It doesn't matter whether
signals the 4WD control module was measured through the in- you wish to use an aftermarket
when the brake is depressed. Two stalled propshaft speed sensors. In gasket because of price or avail-
speed sensors mounted on the 2003 Ford introduced stability con- ability, but if you do, you must in-
transfer case relay propshaft trol to the Explorer /Mountaineer stall a good ground strap on the
speeds to the 4WD control module. models. This is an attempt to safe- transfer case for proper operation.
In the 4X4 automatic mode, power guard the driver against oversteer Another source of poor ground-
is divided to the front and rear conditions and will apply the ing comes from painted units.
propshafts through a ball-and- transfer-case clutch and the an- Many rebuilders paint their fin-
ramp-style internal clutch pack. tilock-braking system to keep the ished units for better presentation
The control module controls the vehicle on its intended path of to the customer as well as for iden-
duty cycle to the clutch pack, send- travel. tification. We have found ground-
ing 95 % of the output to the rear The reason that you need to be ing problems in both the 4405 and
propshaft under normal driving aware of this is that in the 2003 and 4411 units caused by heavy coat-
conditions. If the computer notices 2004 models, the speed sensors on ings of paint on the mounting
a difference in propshaft speeds, the transfer case are present but flange for the transfer case to the
the duty cycle to the clutch pack are NOT active. If you look at the cross member and in the threaded
will be increased to send more circuit illustrations on pages 34 holes for the mounting bolts.
power to the front propshaft until and 35, you will see circuits that Masking these areas before paint-
the shaft speeds are equal, and are described as "with or without ing will provide a clear ground
then the clutch will go back to min- stability control." You must deter- path and eliminate the problem.
imum duty cycle. mine whether the vehicle has sta- In the 2005 model year the BW
As with any "automatic" or ac- bility control before starting any 4411 eliminated the speed sensors
tive transfer case, tire size and diagnosis to trace out a problem on the transfer case, as apparently
pressures are critical to proper op- properly. stability control was added to all
eration. Do not try to diagnose one With the introduction of the models. The 2005-and-up
of these units without first measur- 4411, a factory-installed gasket be- BorgWarner model number on the
ing the tire diameters with a stag- tween the transmission and the ID tag mounted on one of the
ger gauge or a tape around the front case of the transfer case is transfer-case attaching bolts is 4411
center of the tread on each tire and used. Various suppliers have dis- 000 013. Be careful if you are swap-
making sure each tire has the same tributed aftermarket gaskets in ping a late-model 4411 transfer
pressure. A size difference be- their overhaul kits, and problems case from a junkyard into an earli-
tween tires of as little as one-quar- soon began. Our tech-line phone er vehicle that does not have stabil-
ter inch will create trouble codes traffic went wild, with complaints ity control, because the early unit
and improper diagnosis. of "flashing mode-switch indicator will not function without the speed
In the 4X4 high and low ranges, lights" after a rebuild of the trans- sensors working.
the control module will lock the mission or transfer case. On another note, on both the
clutch pack into full duty cycle, During our research to find a fix 4405 and 4411 models, make sure
sending a 50 / 50 power split to the for this condition it became appar- that you lube the O-rings on the
prop shafts. In the low mode, a ent that the aftermarket gaskets speed sensors and twist the sen-
planetary system produces a gear did not provide a proper ground sors side to side when installing to
reduction. The vehicle should not path between the transmission and make sure they are flush with the
be used in anything other than the the transfer case. Early on we case. It is very easy to cock the
automatic 4X4 mode on hard, dry solved the problems by having the speed sensors on installation. This
pavement. Both 4x4 high and low shops install a ground strap be- will produce a high-pitched whine
should be used only in snow, ice or tween the transfer case and the in operation as the speed sensor
off-road conditions on soft ground chassis, which cured the problem. hits the tone wheel.
to prevent driveline windup. It is Further examination revealed that Little things mean a lot; if you
always smart to ask your customer the factory gasket has two metal pay attention to the details the big
in which mode they drive, as you washers molded into it to complete problems will go away. m
will find more than one customer the ground path, but the aftermar-
who is using the system incorrectly ket gaskets did not have this.
and believing that the transfer case Obviously, any electrically con-
has an internal problem. trolled mechanism must have a
In 2002, when Ford switched to proper ground path to complete a
©2008 Transmission Digest. Reproduced with permission. For subscription information call 800-274-7890