Transfer Case Technical Discussion

[SierraBronco]

The inner sleeve also moves as well otherwise it wouldn't have a spring attached to the four prong washer behind it
I think it works like this, for the first portion of the movement the squish is on the clutch plates themselves then once it gets to a certain point it begins to slide the inner splined sleeve the last portion of the movement which causes the engagement of the splines at the same place the gear has the splines

Could you draw what part you’re referring to on the picture? Brain no haz understand

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[BigMeatsBronco]

this part slides

and engages with the same splines as this part.

which is the inside edge of this part

So in 4H or 4L they share the same female splines ...

 

[Snacktime]

These bottom teeth attached to shield on the front drive chain gear.

Fit into the shell

Which does not key into the splined drive

The friction coated disks key into the center and steels key into the shell no mechanical connection to the front drive sprocket.

 

[SierraBronco]

These bottom teeth attached to shield on the front drive chain gear.

Fit into the shell

Which does not key into the splined drive

The friction coated disks key into the center and steels key into the shell no mechanical connection to the front drive sprocket.

This is what it looks like to me also. None of those pieces are actually sliding along the shaft. Just the internal parts of the clutch that are fixed on the spline.

 

[Snacktime]

This dude is getting a million views just from me lol

 

[BigMeatsBronco]

These bottom teeth attached to shield on the front drive chain gear.

Fit into the shell

Which does not key into the splined drive

The friction coated disks key into the center and steels key into the shell no mechanical connection to the front drive sprocket.

I

This is what it looks like to me also. None of those pieces are actually sliding along the shaft. Just the internal parts of the clutch that are fixed on the spline.

Maybe, but it looks like it functions like this...especially because the splines on the side of the front drive gear are the SAME shape and size and number of splines as the inner sleeve

 

[SierraBronco]

I

Maybe, but it looks like it functions like this

These are engaging into the clutch housing if I’m interpreting the picture correctly?

 

[BigMeatsBronco]

it also appears this sleeve moves

inside of here

 

[SierraBronco]

**orders Braptor transfer case**

 

[5GENIDN]

it also appears this sleeve moves

inside of here

I think... and again I could easily be wrong but I think... that spring is exerting movement down not up... I think it is the return spring for the pressure plate.

 

[BigMeatsBronco]

I think... and again I could easily be wrong but I think... that spring is exerting movement down not up... I think it is the return spring for the pressure plate.

The shaft has to be able to split or disconnect or de- spline at some point there ...here's the reason, how else would you get reduction gearing in low range to the rear drive line Shaft or either of them, unless before that clutch it can decouple itself from 1:1 and become 3:1... the center shaft cannot be solid or it would not work

 

[ScLeCo]

Watching this thread eagerly as I was sad lately not having anything to spend thousands of dollars on for my Bronco.

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.

Very familiar with the shitty BW 44-44 transfer cases. I toasted mine drag racing my truck launching in 4wd. The "fix" was just dropping the BW 44-45 that came in lower trims. No part time 4wd but actual lock up when in 4 high.

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

They did? Do you remember what it was (part/model number)? I don't recall them coming out with a fix.

I think I actually still have my old BW 44-44 laying around somewhere.

 

[BigMeatsBronco]

It's become obvious to me that these two shafts splines ( inner and outer) are capable of rotating at different speeds, and most likely couple together with the sliding sleeve

 

[5GENIDN]

The shaft has to be able to split or disconnect or de- spline at some point there ...here's the reason, how else would you get reduction gearing in range to the rear drive line Shaft or either of them, unless before that clutch it can decouple itself from 1:1 and become 3:1... the center shaft cannot be solid or it would not work

Oh agree but that is on the other side of the case isn't it? That should be like the simple old gears of the old transfer cases.... I would hope it is happening downstream of the clutch pack but for some reason I doubt it. I bet it is upstream... And that would place considerably more torque on the clutches. Should be able to tell by aligning the input with this power shaft... If the input is aligned with this shaft the gear reduction would have to be down stream... If it is not then the reduction is upstream. (probably)

 

[BigMeatsBronco]

These are engaging into the clutch housing if I’m interpreting the picture correctly?

I believe that portion is the planetary gear set that gives us 3:1, by engaging the two keys on either side, depending on where the motor pushes that sleeve back depends on if it engages BOTH then its 1:1, engage only 1/2 way and it likley reverts to 3:1...the blue shaft shows 3 lines at the wide point which would make sense, first is input side, inner center is for rear drive, and goes through the hollow outer (rearward) shaft for front engagement.

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