Transfer Case BW4406 with Shift Motor & Speedo for 1996-1998 E-Shift

Description

Engineered for full-size truck platforms, the BorgWarner BW4406 Transfer Case delivers high-torque four-wheel drive power transfer across 1996 to 1998 light-duty commercial vehicles. This unit accepts 420 continuous horsepower at 4,200 input RPM, deploying a 2.64:1 low gear reduction ratio. Mode shifting runs through an exterior electric shift motor paired with a gear-driven speedometer sender port.

Die-cast magnesium housing sections enclose high-tensile planetary gear clusters manufactured from case-hardened 8620 alloy steel. Mechanical engagement relies on heavy-duty bronze synchronizer rings and dual hardened steel shift forks for positive gear retention. The reservoir holds 2.0 quarts of Mercon ATF, cooled through natural convection across external heat-dissipation fins. Bellhousing attachment utilizes a standard circular six-bolt transmission pattern paired with a 31-spline female input drive hub.

Key Features of BorgWarner BW4406

Fleet operators buy BorgWarner BW4406 transfer case units to handle severe trailer towing loads across rugged marine shipyards. Exceptional mechanical gear reduction prevents clutch wear on primary automatic transmissions during steep ramp pulls.

• Massive 2.64:1 planetary reduction gear delivers extreme low-range tractive torque for hauling heavy vessel cradles.
• Electric 12-volt encoder shift motor provides positive driver-selected shifting between two-wheel and four-wheel modes.
• Built-in speedometer drive gear maintains accurate instrument speed readings for legacy truck gauge clusters.
• Reinforced steel selector forks prevent shift fork pad deflection under severe manual transfer torque loads.
• High-strength link-belt drive chain transfers full engine power to the front output flange without stretching.
• Cast magnesium alloy casing delivers superior strength-to-weight ratios while resisting road chemical corrosion.
• BorgWarner BW4406 internal rotary trochoid pump delivers continuous high-pressure oil to upper shaft bearings.
• Precision 31-spline input gear collar mates with heavy-duty truck transmissions to resist spline stripping.

Mechanical Torque Transfer Dynamic Capacities

Under maximum crawler load, this heavy transfer case withstands 1,850 lb-ft of continuous input torque through high-contact helical planetary gears. An integrated mechanical trochoid pump channels fluid straight through the main output shaft, holding operating sump temperatures between 155°F and 185°F under full gross vehicle weight ratings. Total thermal dissipation across the ribbed magnesium housing equals 2.5 kW. High-range direct drive maintains an efficient 1.00:1 ratio, turning driveshafts without unwanted parasitic losses.

Shaft Flange Mounting Alignments

Rear drive exits through an integrated slip yoke housing, while the front driveshaft connects to a four-bolt companion flange featuring a 3.25-inch bolt circle diameter. Internal deep-groove thrust bearings absorb up to 4,800 pounds of continuous axial shaft thrust. Maximum allowable runout at the companion flange face stays below 0.0025 inches total indicator reading.

Shift Sequencing Maintenance Requirements

Engaging low-range four-wheel drive requires stopping the truck completely, applying foot brakes, and selecting transmission neutral position. This mechanical transfer case is not engineered for full-time all-wheel drive operation across dry concrete or asphalt roads. Fleet mechanics must check electrical terminal connections and clean foreign debris from the vent line.

• Examine transmission fluid level at the upper inspection plug each shift.
• Drain fluid and wipe internal collection magnet clean every 500 hours.
• Check electric shift motor mounting bolts and inspect wire plugs every 12 months.

Warranty Statement Package Manifest

Every commercial driveline unit carries a verified 1-Year commercial limited warranty against mechanical failure. The heavy wood shipping crate holds the bare transfer case unit, pre-installed electric shift motor, speedometer drive sensor, threaded drain plugs, and comprehensive installation literature.