Subject: Wear caused by steel shift rail
Unit: BorgWarner 44-05/44-06 transfer case
Vehicle Application: Ford trucks
Essential Reading: Rebuilder,
Author: Pete Luban, ATSG
The BorgWarner 44-05 and 44-06 transfer case used in Ford trucks is known to suffer from case-wear issues. Because the case halves are magnesium they tend to wear in the pocket that supports the steel shift rail (Figure 1) that holds the shift and mode forks.
In most instances this damage requires replacement of the case halves or replacement of the entire transfer case.
Because the price of either of these options can be considerable, one shop came up with a fix that seems to work out well. The case half in Figure 2 shows the shift-rail damage that occurs to the case half.
Figures 3 and 4 show the fix that this shop came up with.
In case you are wondering what to do with those 350 output-shaft pilot bushings that are collecting dust, you install one in the damaged hole in the transfer-case half. The shop uses the reamer that is used for reaming the servo-piston pin bores in the 5R55W transmissions. Use some Loctite® 609 bearing-mount compound on the bushing to ensure that it will not turn or walk out, and you’re good to go.
According to the shop, the success rate of this repair is excellent, and it surely gives you an option for a cost-effective repair.
Special thanks to Darryl from Econo Transmission in Wilmington, N.C., for sharing the fix for this problem.