Identification Guide to BorgWarner Transfer Cases - Transmission Digest

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Identification Guide to BorgWarner Transfer Cases

One of the most time-consuming and annoying problems associated with manual-transmission and transfer-case repair is unit identification. It is difficult to diagnose, buy parts or remanufactured units, and create a correct estimate for the customer when you cannot identify which unit you are working on. All units leave the factory well marked with decals, metal ID tags or both, but through use, weather and previous repairs, many of these ID devices become illegible or non-existent.

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By Mike Weinberg

Up to Standards

  • Author: Mike Weinberg, Contributing Editor

One of the most time-consuming and annoying problems associated with manual-transmission and transfer-case repair is unit identification. It is difficult to diagnose, buy parts or remanufactured units, and create a correct estimate for the customer when you cannot identify which unit you are working on. All units leave the factory well marked with decals, metal ID tags or both, but through use, weather and previous repairs, many of these ID devices become illegible or non-existent.

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This article reviews all the BorgWarner TorqTransfer System transfer cases currently in production, pairing them with the vehicle models in which they are used and providing descriptive details to help you make sure of what you have in the shop. This is only a guide, and you always must be cautious of mixed and matched units and parts, and “gifts” from junkyards and various shoemakers who have worked on the vehicle previously. One of the most-important questions to ask your customer before getting into a repair is, “Has anyone worked on this transfer case before?” This is really good information to have before you jump into the deep end of the pool.

The units are arranged in numerical order, and you will find many that you are familiar with, some new numbers and some units that are probably export only. Nevertheless, you can’t tell the players without a scorecard.

1354 Transfer Case

  • Application: Ford Ranger, Explorer Sport Trac, Mazda B series
  • Configuration: part time
  • Low Range ratio: 2.48-1
  • Lube system: internal gerotor pump
  • Fluid type: ATF
  • Dry weight: 67 lbs.
  • Fluid capacity: 1.2 liters
  • GVW rating: 5,500 lbs.
  • Shift pattern: 2H, 4H, N, 4L
  • Shift control: electrical or mechanical
  • 4WH: shift on the fly

44-02 Transfer Case

  • Application: Hyundai Starex
  • Configuration: part time
  • Low Range ratio: 2.48-1
  • Lube system: internal gerotor pump
  • Fluid type: ATF
  • Dry weight: 63 lbs.
  • Fluid capacity: 1.2 liters
  • GVW rating: 5,500 lbs.
  • Shift pattern: 2H, 4H, N, 4L
  • Shift control: electrical
  • 4WH: shift on the fly

44-06 Transfer Case

  • Application: Ford F-series
  • Configuration: part time
  • Low Range ratio: 2.64-1
  • Lube system: internal gerotor pump
  • Fluid type: ATF
  • Filled Weight: 98.5 lbs.
  • Fluid capacity: 1.9 liters
  • GVW rating: 7,200 lbs.
  • Shift pattern: 2H, 4H, N, 4L (mechanical part time)
  • 2H, 4H, 4L (electric part time)
  • Shift control: mechanical or electrical

44-08 Transfer Case

  • Application: Ssangyong-Korando, Musso, Rexton
  • Configuration: part time
  • Low Range ratio: 2.48-1
  • Lube system: internal gerotor pump
  • Fluid type: ATF
  • Fluid capacity: 1.2 liters
  • Dry weight: 68 lbs.
  • GVW rating: 6,800 lbs.
  • Shift pattern: 2H, 4H, N, 4L
  • Shift control: electrical
  • 4WH: shift on the fly

44-09 Transfer Case

  • Application: Mercedes Benz M class
  • Configuration: full time
  • Low Range ratio: 2.64-1
  • Lube system: internal gerotor pump
  • Fluid type: ATF
  • Dry weight: 89 lbs.
  • Fluid capacity: 1.5 liters
  • GVW rating: 5,800 lbs.
  • Differential controls: open
  • Torque split: front 48%, rear 52%

44-10 Transfer Case

  • Application: Lincoln Aviator, Mercury Mountaineer
  • Configuration: full time
  • Lube system: induction
  • Fluid type: ATF
  • Dry weight: 64 lbs.
  • Fluid capacity: 1.3 liters
  • GVW rating: 5,500 lbs.
  • Center differential: Planetary
  • Differential control: Viscous coupling unit
  • Torque split: Front 35%, rear 65%

44-11 Transfer Case – 1 speed, Torque on demand

  • Application: Lincoln Aviator
  • Configuration: Torque on demand
  • Lube system: internal gear rotor pump
  • Fluid type: ATF
  • Dry weight: 62 lbs.
  • Fluid capacity: 1.42 liters
  • GVW rating: 5,500 lbs.
  • Shift pattern: A4WDH-4H
  • Shift control: electrical

44-1 1 Transfer Case – 2 speed, Torque on demand

  • Application: Ford Explorer
  • Configuration: Torque on demand
  • Low Range ratio: 2.48-1
  • Lube system: gerotor pump
  • Fluid type: ATF
  • Dry weight: 74 lbs.
  • Fluid capacity: 1.42 liters
  • GVW rating: 5,500 lbs.
  • Shift pattern: A4WD-4H-4L
  • Shift control: electrical

44-16 Transfer Case

  • Application: Ford Expedition, Lincoln Navigator
  • Configuration: Torque on demand
  • Low Range ratio: 2.64-1
  • Lube system: gerotor pump
  • Fluid type: ATF
  • Filled weight: 93 lbs.
  • Fluid capacity: 1.9 liters
  • GVW rating: 7200 lbs.
  • Shift pattern: 2H, 4WD, 4H, 4L, Torque on demand
  • Shift control: electrical

44-22 TOD Transfer Case

  • Application: lsuzu Axiom
  • Configuration: Torque on demand
  • Low Range ratio: 2.48-1
  • Lube system: gerotor pump
  • Fluid type: ATF
  • Dry weight: 78 lbs.
  • Fluid capacity: 1.9 liters
  • GVW rating: 6,000 lbs.
  • Shift control: electric
  • Shift pattern: 2H, 4H, N, 4L

44-23 TOD Transfer Case

  • Application: Ssangyong-Korando, Musso, Rexton
  • Configuration: Torque on demand
  • Low Range ratio: 2.48-1
  • Lube system: gerotor
  • Fluid type: ATF
  • Dry weight: 82.2 lbs.
  • Fluid capacity: 1.42 liters
  • GVW rating: 5,553 lbs.
  • Shift pattern: 4H, 4L
  • Shift control: electrical

44-24 Transfer Case

  • Application: Hyundai Terracan, Kia Sorento
  • Configuration: part time and Torque on demand
  • Low Range ratio: 2.48-1
  • Lube system: gerotor pump
  • Fluid type: ATF
  • Dry weight: 79.3 lbs.
  • Fluid capacity: 1.42 liters
  • GVW rating: 5,553 lbs.
  • Shift pattern: 4H, 4L
  • Shift controls: electrical

4-26 ESOF Transfer Case

  • Application: Ssangyong-Korando, Musso, Rexton
  • Low Range ratio: 2.48-1
  • Lube system: gerotor pump
  • Fluid type: ATF
  • Dry weight: 79.6 lbs.
  • Fluid capacity: 1.6 liters
  • GVW rating: 5,500 lbs.
  • Shift pattern: 2H, 4H, N, 4L
  • Shift control: electrical
  • 4WH: shift on the fly

44-26 TOD Transfer Case

  • Application: Ssangyong-Korando, Musso, Rexton
  • Configuration: Torque on demand
  • Low Range ratio: 2.48-1
  • Lube system: gerotor pump
  • Fluid type: ATF
  • Dry weight: 73.6 lbs.
  • Fluid capacity: 1.6 liters
  • GVW rating: 5,553 lbs.
  • Shift pattern: 4H, 4L
  • Shift control: electrical

44-73 Transfer Case

  • Application: Chevrolet Express, GMC Savana
  • Configuration: full time
  • Lube system: splash
  • Fluid type: ATF
  • Dry weight: 70.8 lbs.
  • Fluid capacity: 1.4 liters
  • GVW rating: 7,300 lbs.
  • Center differential: Planetary
  • Differential control: Viscous clutch
  • Torque split: front 35%, rear 65%

44-76 Transfer Case

  • Application: Cadillac SRX
  • Configuration: full time
  • Lube system: splash
  • Fluid type: ATF
  • Dry weight: 48.1 lbs.
  • Fluid capacity: 0.5 liter
  • GVW rating: 6,100 lbs.
  • Center differential: planetary
  • Differential control: open
  • Torque split: front 50%, rear 50%

44-79 Transfer Case

  • Application: Cadillac STS
  • Configuration: full time
  • Lube system: splash
  • Fluid type: ATF
  • Dry weight: 48.1 lbs.
  • Fluid capacity: 0.5 liter
  • GVW rating: 6,100 lbs.
  • Center differential: planetary
  • Differential controls: open
  • Torque split: front 40%, rear 60%

44-81 Transfer Case

  • Application: Cadillac Escalade, GMC Yukon Denali
  • Configuration: full time
  • Fluid type: ATF
  • Dry weight: 61.1 lbs.
  • Fluid capacity: 1.4 liters
  • GVW rating: 7,200 lbs.
  • Center differential: Planetary
  • Differential control: open
  • Torque split: front 40%, rear 60%

44-82 Transfer Case

  • Application: Chevrolet Tahoe, Suburban, GMC Yukon, Yukon XL
  • Configuration: full time
  • Low Range ratio: 2.64-1
  • Lube system: gerotor pump
  • Fluid type: ATF
  • Dry weight: 82.7 lbs.
  • Fluid capacity: 1.4 liters
  • GVW rating: 7,200 lbs.
  • Shift pattern: 4H, N, 4L lock
  • Shift control: electrical
  • Center differential: planetary
  • Differential control: open
  • Torque split: front 40%, rear 60%

44-84 Transfer Case

  • Application: Hummer H2
  • Configuration: full time
  • Low Range ratio: 2.64-1
  • Lube system: gerotor pump
  • Fluid type: ATF
  • Dry weight: 90 lbs.
  • Fluid capacity: 1.4 liters
  • GVW rating: 8,600 lbs.
  • Shift pattern: 4H, 4H lock, N, 4L lock
  • Shift controls: electrical
  • 4WH-Lock: shift on the fly
  • Center differential: planetary
  • Differential control: open
  • Torque split: front 40%, rear 60%

ITM 1

  • Application: Hyundai Santa Fe
  • Configuration: self-contained, lightweight torque-transfer device for on-demand 4WD
  • Torque capacity: 2,000 N·m
  • Weight: 19.6 lbs.
  • Lubricant type: ATF, fill for life

ITM 2

  • Application: Acura MDX, Honda Pilot
  • Configuration: electronically controlled secondary-axle assembly
  • Torque capacity: 1,500 N·m
  • Weight: 90.3 lbs.
  • Lubricant: Mobil 424

As you can see from the listing, there are many new transfer cases now in production, and more will surely follow. The trend toward all-wheel-drive and four-wheel-drive vehicles is increasing, and it is not too great a stretch to believe that in the next decade about 80% of all vehicles will have some form of four-wheel drive. This is an area of growth that you must become familiar with to take advantage of the business available.

“Torque on demand” is a registered trademark of BorgWarner TorqTransfer Systems. This is a torque-distribution system that automatically and smoothly delivers four-wheel-drive operation as required by computer controls and patented modulating clutch. The information is interpreted by the computer system, which adjusts the amount of power delivered to the front wheels up to 50 times a second. This system is designed to be fully compatible with the ABS, traction control, stability control, and automatic- and manual-transmission systems that are part of the overall vehicle design. This means that all diagnostic routines must take into account the various integrated vehicle systems, and tire sizes and pressures.

This is an obvious area of growth for our industry and will be a big part of your business future.

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