Transfer Case Technical Discussion

[Snacktime]

@SierraBronco every clutch failure I have seen so far seems to comment on how burned up the clutches are. Might even want to change the motor driving the clutches as it looks to be torque sensitive. I have watched this video dozens of times makes me wonder if overfilling by 1/2 quart might be worth it.

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[SierraBronco]

@SierraBronco every clutch failure I have seen so far seems to comment on how burned up the clutches are. Might even want to change the motor driving the clutches as it looks to be torque sensitive. I have watched this video dozens of times makes me wonder if overfilling by 1/2 quart might be worth it.

This is the video where I had the “ah ha!” moment realizing there was no mechanical lockup! Actually sent it to @5GENIDN this morning with the timestamps to look at to show it.

When I replace the clutch I’m going to leave the Tcase installed. Doesn’t look like it should be too much of a hassle especially with the extra clearance of the body lift. But I’m certainly not opposed to pumping as much fluid in as possible until it seems the fill rate doesn’t match the spill rate then throwing the plug on as quickly as I can…

 

[5GENIDN]

This is the video where I had the “ah ha!” moment realizing there was no mechanical lockup! Actually sent it to @5geniden this morning with the timestamps to look at to show it.

When I replace the clutch I’m going to leave the Tcase installed. Doesn’t look like it should be too much of a hassle especially with the extra clearance of the body lift. But I’m certainly not opposed to pumping as much fluid in as possible until it seems the fill rate doesn’t match the spill rate then throwing the plug on as quickly as I can…

Yep same video... I am seriously disappointed. I should have know but I did not. I thought our T case locked up in 4H and 4L but not the case.

 

[SierraBronco]

Yep same video... I am seriously disappointed. I should have know but I did not. I thought our T case locked up in 4H and 4L but not the case.

I mean…that is what makes sense.

 

[Snacktime]

My first experience with these clutches was in the Ram 1500s when helping my neighbor pull out a stuck truck with a 5th wheel. Dam truck would spin the rear tires in 4 lo and not the front. Ended up spending a few days trying to figure out what was wrong. Which was absolutely nothing! As the system never did give enough voltage to ever fully lock the clutches.

This is a gem with amazing photos! Notice anything?
https://www.transmissiondigest.com/snow-plowing-bw-44-44-transfer-case-failures/

I have a firm belief that current Bronco awd transfer case failures are just smaller issue in the clutch pressure. I would really focus on changing the actuator at the same time purely as a precautionary measure.

 

[5GENIDN]

My first experience with these clutches was in the Ram 1500s when helping my neighbor pull out a stuck truck with a 5th wheel. Dam truck would spin the rear tires in 4 lo and not the front. Ended up spending a few days trying to figure out what was wrong. Which was absolutely nothing! As the system never did give enough voltage to ever fully lock the clutches.

This is a gem with amazing photos! Notice anything?
https://www.transmissiondigest.com/snow-plowing-bw-44-44-transfer-case-failures/

I have a firm belief that current Bronco awd transfer case failures are just smaller issue in the clutch pressure. I would really focus on changing the actuator at the same time purely as a precautionary measure.

I would guess you are absolutely correct. Good call! Disappointing as it is.

 

[SierraBronco]

My first experience with these clutches was in the Ram 1500s when helping my neighbor pull out a stuck truck with a 5th wheel. Dam truck would spin the rear tires in 4 lo and not the front. Ended up spending a few days trying to figure out what was wrong. Which was absolutely nothing! As the system never did give enough voltage to ever fully lock the clutches.

This is a gem with amazing photos! Notice anything?
https://www.transmissiondigest.com/snow-plowing-bw-44-44-transfer-case-failures/

I have a firm belief that current Bronco awd transfer case failures are just smaller issue in the clutch pressure. I would really focus on changing the actuator at the same time purely as a precautionary measure.

Geeeeeeeze

Suncoast did mention possibly adding another disk into the pack to increase pressure but wasn’t sure if it would be possible until seeing everything. It’s on the list of things to talk about with the Ford buddy. Perhaps @Ducati1098 or @flip would have an opinion?

 

[SierraBronco]

How today has gone on this thread. I’m James. @Snacktime is Richard.

 

[Ducati1098]

Geeeeeeeze

Suncoast did mention possibly adding another disk into the pack to increase pressure but wasn’t sure if it would be possible until seeing everything. It’s on the list of things to talk about with the Ford buddy. Perhaps @Ducati1098 or @flip would have an opinion?

Your guess is as good as mine on that one. Not something I’ve ever seen or tried.
Pretty common thing for transmissions though. So if there’s enough room, I don’t see it hurting anything to add another one If possible.

 

[orion]

From @Snacktime link.

This is what we need plus a lower low gear ratio gear set! #3 and the bold below it. From the looks of it, it removes the clutches and makes it part time 4x4!!!

I'm going to read that in more depth this evening!

Edit to add: That is exactly what this is! Nice find @Snacktime ! Now, who's going to make it happen for ours? @BigMeatsBronco or perhaps you @SierraBronco

 

[SierraBronco]

From @Snacktime link.

This is what we need plus a lower low gear ratio gear set! #3 and the bold below it. From the looks of it, it removes the clutches and makes it part time 4x4!!!

I'm going to read that in more depth this evening!

Edit to add: That is exactly what this is! Nice find @Snacktime ! Now, who's going to make it happen for ours? @BigMeatsBronco or perhaps you @SierraBronco

Show me where to buy it! I clicked through their stuff and couldn’t find anything

 

[5GENIDN]

Show me where to buy it! I clicked through their stuff and couldn’t find anything

That is for the Dodge....

 

[SierraBronco]

That is for the Dodge....

Yeah. Couldn’t find anything for Bronco*

 

[5GENIDN]

Yeah. Couldn’t find anything for Bronco*

I do not think there is anything yet... BUT I know you have been discussing this issue with people that may look to this design as inspiration... OR this company may determine this enough a market to offer it up... possibilities....

 

[Snacktime]

The part was never fully developed. Ram came out with an updated transfer case that was a drop in replacement.

Maybe the right size shim in the mechanism would increase the tension. A feeler gauge and calipers would be where I start. Looks like there is enough play that you could get a few more thousandths take up which might be all you need.

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