transfercase diagram

[chrisbh17]

Borg Warner makes good stuff, after seeing all the videos and all of the complaints (and praises) of the xfer case, I have to believe its crappy programming on FCAs part.

Ford uses a variation of the 44-44 and everyone loves it there.

I know there are manufacturing tolerances involved (not a whole lot, per the service manual, but I imagine one or two could add up) so engagement might be delayed on some vs. others, but it just doesnt seem like the programming matches the xfer case at all. If thats the case, FCA could actually fix it, IF THEY WANTED TO.

@Brandon-w Honestly I think the price might be a bit high, but I don;t know your costs, I dont know shipping from CA to US and most of all Im a cheap ass The biggest question I have is if the encoder motor will burn up with 12V constant applied to it. I think only time will tell (a month of Canadian use is probably a decent test!)

 

[Brandon-w]

Yeah getting parts and stuff is a bit more expensive just a number I'm Throwing out there as of now it's nothing solid. As for the encoder motor it only turns on to shift the t case and that's it. Once it's shifted into 4 or 4 low it shuts off. The clutches will not overheat unless they're slipping so in theory with clutches locked up it would Make less heat.

I totally agree it's a decent transfer case the problem is FCA putting their twist on it, they're thinking that modulating abs to lock and unlock wheels while in 4 wheel drive would accomplish what? I say their system is harder on brakes and clutches, are they just setting this up To fail so they make more money off warranty? I would 100% bet there is electronic programming that could make this system work good like in the ford's.

Ps. Don't be a cheap ass good things are hard to come by. And so far there's alot of time put into fooling around to make this work lol. On that note times are tight I just got laid off.

 

[Hemi395]

@Brandon-w has just proven this isn't a BW problem, it's FCA nerfing it with their programming

Such BS.

 

[Brandon-w]

This is my truck shortly after I got it. I can't wait to fix this.

Wow it doesn't want to scratch its way anywhere at all. :/

 

[Hemi395]

It will if you give it gas but just sitting there it's basically 2wd. Stupid.

 

[chrisbh17]

And I hear Rockland Standard has heavy duty clutches available. They have reportedly held up even to snowplowing.

This mod + those clutches? Almost dont need a 44-45 lol.

 

[Brandon-w]

It will if you give it gas but just sitting there it's basically 2wd. Stupid.

I almost thought it was in 2 wheel! that's really sad they built them like that.

 

[Wild one]

Oh nice I like it down there! I don't have Facebook Though. As you said too many idiots, I call them Google scholars spouting about what they don't know or have experienced. Lol.

That's to bad you don't do facebook,as you're missing a ****load of guys that might buy the harness.There's not all that many prairie Canucks on here,but they're on facebook,and by not posting on facebook you're not gonna reach them.You might even get the odd guy drag racing his 4X4 wanting your harness,lol.

 

[Brandon-w]

That's to bad you don't do facebook,as you're missing a ****load of guys that might buy the harness.There's not all that many prairie Canucks on here,but they're on facebook,and by not posting on facebook you're not gonna reach them.You might even get the odd guy drag racing his 4X4 wanting your harness,lol.

That is valid. I guess I could start a FB account for that. I know it would really help the oil patch guys around here alot that have these systems.

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[Brandon-w]

On a side note, probly should do this on another thread but oh well. I'm thinking about taking my zf215 front diff apart and seeing what I can do for a locker. Maybe even see if I can add more clutches to the spiders or something like that. I have emailed around the globe looking for a Locker or a limited slip with nothing. Guys say it would Be hard to steer which is true but like I said before like with this t case mod it turns into a get out of a situation tool. Seeing as the front axle has a disconnect mods like this wouldn't affect drivability in 2 wheel but would give you that extra bit of traction in the odd situation. Funny the whole reason I've done this transfer case mod is because I got stuck in a foot of snow hauling a 24' car hauler and realized no matter what I did the front wouldn't activate until I was on the throttle. Anyways more food for Thought. [emoji48]

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[Hemi395]

And I hear Rockland Standard has heavy duty clutches available. They have reportedly held up even to snowplowing.

This mod + those clutches? Almost dont need a 44-45 lol.

Now this is an idea!

 

[chrisbh17]

Yeah getting parts and stuff is a bit more expensive just a number I'm Throwing out there as of now it's nothing solid. As for the encoder motor it only turns on to shift the t case and that's it. Once it's shifted into 4 or 4 low it shuts off. The clutches will not overheat unless they're slipping so in theory with clutches locked up it would Make less heat.

I totally agree it's a decent transfer case the problem is FCA putting their twist on it, they're thinking that modulating abs to lock and unlock wheels while in 4 wheel drive would accomplish what? I say their system is harder on brakes and clutches, are they just setting this up To fail so they make more money off warranty? I would 100% bet there is electronic programming that could make this system work good like in the ford's.

Ps. Don't be a cheap ass good things are hard to come by. And so far there's alot of time put into fooling around to make this work lol. On that note times are tight I just got laid off.

hehe you got me.

Its still cheaper than swapping to a 44-45 and I can keep my warranty.

If you are able to make it plug and unplug using factory connectors, Im all for it! And since it looks like that is your end goal, count me in for sure.

I dont need the 2WD version, though. Real deal 4WD (when I need it) is good enough for me.

 

[Brandon-w]

Hey everyone so quick update on the harness. I had to go into the back field early thismorning and decided to go off the beaten trail, I hit 4 lock and locked the t case with the switch and headed out into the deep stuff. After about 30 seconds of spinning in the deep stuff the traction control light came on and it disabled its self. Not sure if it was because it could not modulate the front wheels properly or what but when it turned off it seemed to help to let the truck dig more. [emoji846] After I got out I shut off the switch and went back into 2 wheel I drove about 100 meters and the traction control light went out and everything was normal again. If it's going to work like that every time I won't complain as it seems I could pour the throttle to it when it was off.

Also as Chris said above, the rear wheels on most of our trucks seem to have to spin before it will lock The front wheels. I noticed it does this much worse in reverse than in drive but even in drive the system is pretty pathetic. I am trying to get ahold of Borg warner for some specs as dodge and Ford can't answer my questions. I'll keep you guys updated.

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[chrisbh17]

I would be interested to see if there is a stored/pending code on the traction control and to see what that code is. And the fact it "digs more" with traction control off just helps my theory that traction control is overriding the 4WD system in the sense that it gives the rears enough traction to "reset" the ball/ramp on the xfer case. And around and around we go until something gives.

BTW I replied to your thread on the other forum, attached the xfer case wiring diagram. Adding here for posterity

 

[Brandon-w]

Yeah I seen that just replied. Lol
With what guys are saying the switch gives full lock, originally the system would have to spin the tires before it would be locked but now (not confirmed) it feels like with the switch locked it just ramps to full lock as you start moving doesn't seem like. There is any spin. From foreward to reverse if Ur Alittle rammy you can feel it lock hard. The way it's acting there may be a slight delay in lockage but it's nothing like factory was and when it's locked up you have full 4x4 no question about it. Kind of a funny system though.

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[crash68]

One of the things traction control does to help you regain "traction" is to reduce power/back off the throttle. Push and hold the traction control button for 10 seconds till the ESP turns off and see how the transfer case lock works. The ESP will re-engage if the wheel speed goes above 40 mph though.

 

[Brandon-w]

My truck will not shut off the traction control by holding the button for 10 seconds. [emoji20] Tried that a few times. I can hit the button and it'll cut it down by about 20% but it never deactivates when I hold the button. Not sure if it's just a my truck thing or others are like that. My tuner will turn it completely off when I want though.

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[chrisbh17]

My traction control never fully disables either, from what I can tell.

I can press and hold the button for a while, eventually (30+ seconds) the traction control off light will go out. Ive tried spinning the tires after that and I still get the flashy icon on the dash when the wheels are slipping, so something in regards to traction control is still enabled.

I did not know about the 40mph thing, but my wheels didnt spin enough to get up to that speed. Maybe I *drove* past that speed but I cant remember now. I will try it later if I get a chance.

 

[Brandon-w]

So I found this single Push button relay that may work. It might not be 100% optimal but seeing as how the 4x4 selector uses a pulse resistance on one wire to determine 4 different states this could in theory turn on the lock switch activation so it could be manually be turned on when needed and be "locked out" per say when in 2 wheel drive. Just throwing ideas out.

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[Brandon-w]

Like we had talked about before tho it is much simpler to pick Up off of Sig wires for the encoder which this would also work on In Theory. Biggest problem is pretty much idiot proofing it. If I built a latch switch I could use 4x4 and low as inputs to activate and hold the relay and the 2 wheel from encoder to open another relay ground the original circuit and shut it off. Only issue is then when 4auto is selected the encoder motor has already selected 4 wheel drive, this would activate the switch leaving us with the same problem, risking people leaving the switch on. Hmmm [emoji19]

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