Snow plowing = BW 44-44 transfer-case failures
Experience we gain from solving problems generated in the transmission repair industry sheds light on various common failures and allows us to see trends that provide new products to solve design issues.
From 2011 on, Dodge has offered Ram 1500 pickup trucks equipped with the BW 44-44 transfer case. The 44-44 transfer case is a computer controlled “active” full-time transfer case.
BEING A GREAT CLUTCH HITTER
Clutch replacement has always been a steady source of business in the transmission repair shop. More and more general repair facilities are swapping clutches to add to their cash flow. There are a number of OEM quality clutch replacement sets available in the marketplace from LuK, Daikin/Exedy, Valeo, Sachs, etc. that provide OEM parts at reasonable prices. No matter how good the parts are that you are using, the installer has the responsibility for a thorough, proper installation. Anytime a manual trans is removed from the vehicle, the clutch also should be removed and inspected. A few more minutes of labor can produce added revenue from the job, decrease the chances of warranty problems, and ensure that the clutch was not the cause of the transmission failure. It is very important to make sure that the clutch is capable of transferring all of the engine torque to the transmission, and that when the clutch is disengaged there is a complete disconnect of the transmission from the engine torque. A slipping clutch will damage the clutch friction components, a clutch that does not release completely causes notchy, grinding shifts and does immediate damage to the synchronizer and speed gear components in the transmission.
Maximizing Your Return On Tech Calls: Work Smarter, Not Harder
Our industry has morphed into an extremely complex diagnostic and troubleshooting environment. The current design and operation of modern vehicles has become as technical as rocket science. The relationship between the systems that interact to make the vehicle function correctly has grown to a point where even a road test can be very time consuming. Is the problem in the transmission, transfer case or rear? Are there multiple problems that affect inter connected systems or is the problem outside the transmission? To get a proper solution to a complex problem, we need to use a diagnostic routine that follows a set of protocols in a proper order that are structured to be consistent, every time without variation. Working from a consistent structure will prepare you for success without multiple phone calls and wasted time.
Taking the Mystery Out of Clutch Adjustment with Concentric Slave Cylinders
Proper clutch adjustment is a must for correct operation and durability of the clutch components. For many years, clutch engagement and release was performed with a manual linkage or an external hydraulic system. The manual linkages were adjusted by threaded rods that were set to provide proper engagement and proper clutch release, which was relatively simple to achieve. External hydraulic systems used an externally mounted slave cylinder that actuated the clutch fork and were adjustable through a threaded rod from the slave cylinder to the clutch fork. Hydraulic systems have their own challenges, which mainly revolve around proper bleeding technique to ensure that there is no air trapped in the system.
Looking Back and Looking Forward
Another year comes to a close and we need to review the past 12 months and prepare for the coming year. More than a half a century working on cars has taught me that there is no point at which we can stand still without the technology passing us by. Our industry is in a continuing consolidation as larger companies acquire smaller ones to increase their share price. At a certain point, a large corporation cannot increase sales and cut costs fast enough to show growth and increase shareholder value, so acquisition is the path to a bigger, better bottom line. Repair facilities (once called trans shops) now are adding other services to transmission repair to increase their own cash flow and stay in business. The quality of late-model vehicles has improved dramatically due to the advent of computer control and Cad-Cam design. Cars and trucks now are generating fewer warranty claims, which affects the trans shop/repair facilities as well as the car-dealer service departments. Dealerships no longer have the cushion provided by numerous warranty claims, and have become a major competitor to the aftermarket independent shops. As in nature, only the strong survive. How do we survive and increase our profitability and cash flow in this ferocious environment? That is the question to be discussed.
BorgWarner 44-44 Transfer Case from the Electronic Side
Last month we took a look at the BW 44-44 and 44-45 series of transfer cases found in late-model Ram pickups. We continue this month with a look at the electronics that make the 44-44 function. A brief review on this unit leads us to an electronically controlled active full-time transfer case.
Transfer Cases and Tires: How RAM is changing the rules
Looking at the BorgWarner 44-44 and 44-45 transfer cases, we see an evolutionary change that started with the BW4405 and 4411 and has now reached this level of development. The design uses a wet-clutch pack in the transfer case to split torque between the rear and front axles.
The Transmission-Repair Twilight Zone
I have written an awful lot of technical articles over the years, and I thought it might be fun to go over some of the strange events that every transmission-repair shop experiences with customer relations, strange technical issues and the feeling at times that you are in the Twilight Zone. The important issue in handling weird events is to realize you are not alone, that everyone in our business has some similar experiences. It starts with ordinary everyday activity that soon descends into strangeness. Some of these tales are created by the human behavior that we need to deal with every day, whether it involves customers or others who hold themselves out to be professionals.
Getting into the MP3023 Transfer Case
Getting into the MP3023 Transfer Case
Magna Powertrain (MP) is a worldwide manufacturer of components and systems for vehicle manufacturers. It has acquired the New Process and New Venture Gear business and now produces components under the Magna name. GM awarded its transfer-case business to Magna beginning with the 2007 model year. We have done articles before on the various models of MP transfer cases.
PTU: a Different Kind of Transfer Case
The main design parameters for most late-model cars have been front-wheel drive (FWD) with transverse-mounted engines. This is a convenient packaging system for the manufacturer and has been for many years. The current trend of increased safety and performance has made many of the manufacturers add all-wheel drive (AWD), which sends power to the rear wheels for better traction and stability. The traditional transfer case, which divides power to the front and rear axles on vehicles with north/south engine placements, is unusable here.
Entering The Twilight Zone – Strange Problems
Everyday technicians earn their living by solving complex problems. The modern automobile or truck has evolved into a very sophisticated machine in which all parts must function together to perform properly. This means that what used to be a simple three- or four-speed transmission has become entwined with systems that are computer controlled and where an antilock-brake system or suspension system that is not working correctly can have major effects on transmission operations.
NSG370, Jeep’s First 6-Speed Manual Transmission
We have seen many changes in the companies that manufacture automobiles. Chrysler got married to Mercedes, the love affair didn’t last and now Chrysler is part of The Fiat Group. While Chrysler was paired with Mercedes, it chose a German-design six-speed for use in Chrysler vehicles. Thus we saw the NSG350, a six-speed manual transmission fitted to 2005-2008 Jeep Liberty, 2005-to-present Wrangler, 2004-2006 Chrysler Crossfire and the 2006-2008 Dodge Nitro, as well as some Mercedes ML models.
NSG is a German acronym for “new shifting manual transmission,” although you may also say NSG stands for “not so good.” This six-speed manual transmission has an integral bellhousing in the front case and as is common in European design is loaded longitudinally. Fifth gear is 1-1 ratio (direct drive) and sixth is overdriven, so be aware of this when you are diagnosing a problem.
