Vous êtes sur la page 1sur 5

BROUGHT TO YOU BY PRO GEAR &

TRANSMISSION.

FOR PARTS OR SERVICE CALL:

877-776-4600
407-872-1901

~
MERITOR [ROCKWELi:]
._________
l:!Y•N
~-~Fuller
A Roadrange,· SPICER"
IVII.PJ..CK® <$> I l'.::r•N

WWW.PGTTRUCKPARTS.COM

906 W. GORE ST. ORLANDO, FL 32805


PARTS@EPROGEAR.COM
Up Ta §tandards

Subject: The Fine Points of the


Operation and diagnosis
Units:
4411 , 4405 transfer cases
BorgWarner
Vehicle Applications:
Ford Explorer/Mercury
4411 Transfer Case
Mountaineer
Essential Reading :
~ Rebuilder
• Shop Owner ne of the best-

~


Center Manager
Diagnostician
R &R
O selling vehicles
produced by
Ford Motor Co. is the
4WD
Mode-
select
switch

Ford Explorer / Mercury


Author: Mountaineer SUV.
Mike Weinberg, These vehicles started
Rockland Standard Gear production using the
Contributing Editor
BorgWarner 4405 trans-
fer case and had a huge
production run.
In 2002 Ford intro-
duced the BorgWarner
4411 transfer case in
these models. The 4411
is a design evolution of
the 4405 transfer case,
with the principal visu-
al difference being a re-
designed front case
housing that mounts to
the rear of the transmis-
sion. Like the 4405, the
unit is found behind Transfer case
both manual and auto-
matic transmissions.
The major difference
between the two units
is the electronic controls operating the that informs the control module of the
transfer cases. motor position, and an encoder as-
Because of the huge volume of these sembly, which is part of the shift
units it will be necessary to review the motor.
theory of operations of the electroni- The driver selects either 4X4 Auto,
cally controlled "automatic" or active 4WD High or 4WD Low through the
transfer cases. Both the 4405 and 4411 MSS, which will illuminate when in
are called automatic 4WD systems and the 4X4 Low position. Once a selection
share similar components. We have a is made the electronic shift motor
transfer case with a 4WD control mod- turns an internal cam, which moves
ule (ECM), a dash-mounted mode-se- the reduction shift fork to the called-
lect switch (MSS) that allows the for transfer-case position. A position
driver to select various operating sensor in the motor informs the con-
modes and ranges, an electric shift trol module of the position of the
motor with a position-sensing plate motor.

©2008 Transmission Digest. Reproduced with permission. For subscription information call 800-274-7890
--------------~. --------------------------------------
Up Ta §tandards

8 6 4 2
7 5 3 1

4WD Control Module C281a

12 10
17 13 11 9

Pin Circuit Normal


Number(s) Designation/Description Condition/Measurement
CKT 1205 (BK) Ground circuit for trans- 5 ohms or less to chassis ground
1
fer case shift motor
CKT 778 (OG) Transfer case shift motor 10,000 ohms or greater to chassis ground with 4WD control module
2 control circuit between 4WD control and transfer case shift motor disconnected. 5 ohms or less between
module and transfer case shift motor 4WD control module and transfer case shift motor
CKT 762 (YE/WH) Transfer case shift 10,000 ohms or greater to chassis ground with 4WD control module
3 motor position signal return between and transfer case shift motor disconnected. 5 ohms or less between
transfer case contact encoder plate and 4WD control module and transfer case shift motor
4WD control module
CKT 763 (OG/WH) Transfer case shift 10,000 ohms or greater to chassis ground with 4WD control module
4 motor position contact plate encoder sig- and transfer case shift motor disconnected. 5 ohms or less between
nal pos ition four 4WD control module and transfer case shift motor
CKT 764 (BN/WH) Transfer case sh ift 10,000 ohms or greater to chassis ground with 4WD control module
5 motor position contact plate encoder sig- and transfer case shift motor disconnected. 5 ohms or less between
nal position three 4WD control module and transfer case shift motor
CKT 770 (WH) Transfer case shift motor 10,000 ohms or greater to chassis ground with 4WD control module
6 position contact plate encoder signal and transfer case shift motor disconnected. 5 ohms or less between
position two 4WD control module and transfer case shift motor
CKT 771 (VT/YE) Transfer case sh ift 10,000 ohms or greater to chassis ground with 4WD control module
7 motor position contact plate encoder sig- and transfer case shift motor disconnected. 5 ohms or less between
nal pos ition one 4WD control module and transfer case shift motor
CKT 976 (OG) Transfer case clutch field 10,000 ohms or greater to chassis ground with 4WD control module
8 coi l signal return and transfer case disconnected . 5 ohms or less between 4WD con-
trol module and transfer case
CKT 777 (YE) Transfer case sh ift motor 10,000 ohms or greater to chassis ground with 4WD control module
9 control circuit between 4WD control and transfer case shift motor disconnected. 5 ohms or less between
module and transfer case shift motor 4WD control module and transfer case shift motor
CKT 236 (BK/LG) Non-stability assist 10,000 ohms or greater to chassis ground with 4WD control module
10 only. Front output shaft speed sensor and transfer case disconnected . 5 ohms or less between 4WD con-
signal trol module and transfer case
CKT 772 (LB) Non-stability assist only. 10,000 ohms or greater to chassis ground with 4WD control module
11 Rear output shaft speed sensor signal and transfer case disconnected. 5 ohms or less between 4WD con-
trol module and transfer case
CKT 359 (GY/RD) Non-stability assist 10,000 ohms or greater to chassis ground with 4WD control module
12 only. Output shaft speed sensors ground and transfer case disconnected . 5 ohms or less between 4WD con-
circuit trol module and transfer case
CKT 774 (LG) Non-stabil ity assist only. 10,000 ohms or greater to chassis ground with 4WD control module
13 Output shaft speed sensors power circuit and transfer case disconnected. 5 ohms or less between 4WD con-
trol module and transfer case
CKT 779 (BN) Transfer case clutch 10,000 ohms or greater to chassis ground with 4WD control module
17 power circu it and transfer case disconnected . 5 ohms or less between 4WD con-
trol module and transfer case

©2008 Transmission Digest. Reproduced with permission. For subscription information call 800-274-7890
--------------~. --------------------------------------
Up Ta §tandards

4 3 2 1

Transfer case C350


8 7
11

16 15 14 13

Pin Circuit Normal


Number(s) Designation/Description Condition/Measurement
CKT 770 (WH) Transfer case shift motor posi- 10,000 ohms or greater to chassis ground with 4WD control
1 tion contact plate encoder signal position two module and transfer case shift motor disconnected. 5 ohms or
less between 4WD control module and transfer case shift motor
CKT 772 (LB) Non-stability assist only. Rear 10,000 ohms or greater to chassis ground with 4WD control
2
output shaft speed sensor siqnal module and transfer case
CKT 774 (LG) Non-stability assist only. Rear 10,000 ohms or greater to chassis ground with 4WD control
3 output shaft speed sensor power circuit module and transfer case disconnected. 5 ohms or less
between 4WD control module and transfer case
CKT 236 (BK/LG) Non-stability assist only. 10,000 ohms or greater to chassis ground with 4WD control
4 Front output shaft speed sensor signal module and transfer case disconnected. 5 ohms or less
between 4WD control module and transfer case
CKT 771 (VT/YE) Transfer case shift motor 10,000 ohms or greater to chassis ground with 4WD control
5 position contact plate encoder signal position module and transfer case shift motor disconnected. 5 ohms or
one less between 4WD control module and transfer case shift motor
CKT 359 (GY/RD) Non-stability assist only. 10,000 ohms or greater to chassis ground with 4WD control
6 Rear output shaft speed sensor ground circuit module and transfer case disconnected. 5 ohms or less
between 4WD control module and transfer case
CKT 774 (LG) Non-stability assist only. Front 10,000 ohms or greater to chassis ground with 4WD control
7 output shaft speed sensor power circuit module and transfer case disconnected. 5 ohms or less
between 4WD control module and transfer case
CKT 359 (GY/RD) Non-stability assist only. 10,000 ohms or greater to chassis ground with 4WD control
8 Front output shaft speed sensor ground circuit module and transfer case disconnected. 5 ohms or less
between 4WD control module and transfer case
0CKT 764 (BN/WH) Transfer case shift motor 10,000 ohms or greater to chassis ground with 4WD control
9 position contact plate encoder signal position module and transfer case shift motor disconnected. 5 ohms or
three less between 4WD control module and transfer case shift motor
CKT 762 (YE/WH) Transfer case shift motor 10,000 ohms or greater to chassis ground with 4WD control
10 position signal return between transfer case module and transfer case shift motor disconnected. 5 ohms or
contact encoder plate and 4WD control module less between 4WD control module and transfer case shift motor
CKT 976 (OG) Transfer case clutch field coil 10,000 ohms or greater to chassis ground with 4WD control
11 signal return module and transfer case disconnected. 5 ohms or less
between 4WD control module and transfer case
CKT 763 (OG/WH) Transfer case shift motor 10,000 ohms or greater to chassis ground with 4WD control
13 position contact plate encoder signal position module and transfer case shift motor disconnected. 5 ohms or
four less between 4WD control module and transfer case shift motor
CKT 778 (OG) Transfer case shift motor con- 10,000 ohms or greater to chassis ground with 4WD control
14 trol circuit between 4WD control module and module and transfer case shift motor disconnected. 5 ohms or
transfer case shift motor less between 4WD control module and transfer case shift motor
CKT 777 (YE) Transfer case shift motor control 10,000 ohms or greater to chassis ground with 4WD control
15 circuit between 4WD control module and module and transfer case shift motor disconnected. 5 ohms or
transfer case shift motor less between 4WD control module and transfer case shift motor
CKT 779 (BN) Transfer case clutch power cir- 10,000 ohms or greater to chassis ground with 4WD control
16 cuit module and transfer case disconnected. 5 ohms or less
between 4WD control module and MSS

©2008 Transmission Digest. Reproduced with permission. For subscription information call 800-274-7890
--------------~. --------------------------------------
Up Ta §tandards

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

Vous aimerez peut-être aussi