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|I seem to remember mine grinding into low range from time to time
Pretty sure the brown wire needs to be hooked up to fix that grinding I never hooked mine up instead I turn truck off shift into low then start up again and no grinding
Read this see if it helps
I found this:
What Ford has to say:
The 4406 manual shift and electronics shift transfer cases are three-piece magnesium design. Under normal driving conditions the unit is in 2H, but when desired, the operator may shift into 4H or 4L. The operator may shift from 2H to 4H or from 4H to 2H at any speed up to 88km’h (55mph). The vehicle must be less than 5km/h (3mph), the brake applied, and the transmission in NEUTRAL to shift into 4L. The unit is lubricated by a positive displacement fluid pump that channels fluid flow through holes in the rear output shaft.
The electromagnetic clutch is located inside the case. The clutch is used to spin up the front driveshaft when shifting from 2H to 4H at speed. When the shift lever is moved, it activates the 4WD indicator switch, 4WD electric clutch relay, and the clutch itself. When the TC front and rear output shafts are synchronized, the spring loaded lockup collar mechanically engages the mainshaft hub to the drive sprocket. Finally, the front axle collar is engaged and the clutch is deactivated.
The transfer case is set up as such:
a) 2H -> 4H -> TC Neutral -> 4L
b) 4L -> TC Neutral -> 4H -> 2H
1). When in 2H the floor shifter is pointed towards the dash. The TC lever is pointed all the way back towards the rear of the vehicle.
2). When in 4H the floor shifter is in the middle (pointing towards the sky) The TC lever is also pointed up.
3). When in 4L the floor shifter is towards the drivers seat. The TC lever is pointed towards the front of the vehicle.
2H - 4H: Vehicle can be moving but must be traveling less than 45-60mph. While putting along, under light to moderate throttle shift from 2H - 4H.
4H - 4L: Stop the vehicle. You CANNOT Shift on the FLY from 4H to 4L. Place transmission in Neutral (maybe even Park if you’re having grindage). Wait 10 seconds. Place TC in 4L. Place transmission in gear. You’re now good to go.
4L - 4H: Stop the vehicle. You CANNOT Shift on the FLY from 4L to 4H. Place transmission in Neutral (maybe even Park if you’re having grindage). Wait 10 seconds. Place TC in Neutral. Wait 10 seconds. Pace TC in 4H. Place transmission in gear. You’re now good to go.
4H - 2H: Vehicle can be moving but must be traveling less than 45-60mph. While putting along, under light to moderate throttle shift from 4H - 2L.
2H - 4L: Bad.. Don’t do this..
4L - 2H: Bad.. Don’t do this..
If the transfer case is in the Neutral position then both front and rear driveshaft are unlocked and the vehicle can be towed with all 4 wheels on the ground.
The BW 4406 uses MercronV? apx 2 quarts..
How does the shift linkage "feel". When I pull back from 2H to 4H, there’s a distinct click. If I continue to pull back I would hit a shift block/stop keeping me from accidentally placing the TC into TC Neutral. To go into 4L from 4H I have to move the shift linkage towards my leg, pull down, pull towards console, and pull down into 4L passing straight through TC Neutral. Conversely If I am in 4L I pull to my leg and place in TC Neutral, pull towards console and place in 4H. From 4H I push towards dash into 2H.
When I spin the input shaft (coming from the transmission) with the TC in 2H, there is minimal free play between the input shaft and rear driveshaft. Is this normal?
When I spin the input shaft (coming from the transmission) with the TC in 4H, there is a fair bit free play between the input shaft and rear driveshaft and a lot of in the front driveshaft. Is this normal?
When I spin the input shaft (coming from the transmission) with the TC in 4L, there is a small amount free play between the input shaft and rear driveshaft and a small amount in the front driveshaft. Is this normal?
4L 2.75:1 (approximately)
Last edited on Wed Dec 12th, 2018 02:37 pm by 410customs
I build custom RBV, specializing in drivetrain conversions, wiring, suspension and complete custom trucks