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I am having a little difficulty with the transfer case in my 95 Explorer Limited with control trac 4x4. It seems as if there is a little play in the shaft (I can move it up and down about 1/8 inch). It also leaks fluid out at the rear seal, and I imagine this is because of the play in the shaft, as I just replaced the seal when I replaced the speedo gear about 3 weeks ago. I am wondering if there is some kind of bearing inside the case that might be bad? If so, how do I go about replacing the bearing? One other question I have is I considered replacing the whole transfer case with a used one, but the ones they have for this year, the Borg Warner 1354, looks different than mine. Do the control tracs have a different model?
The 1354 is a part time transfer case that came on '91-'94 Explorers. It sounds like they haven't cross referenced correctly. I want to say that the Borg-Warner 44-05 t-case is the control trac t-case you're looking for, but that might be the AWD t-case for later V8's. Hopefully someone who knows the 2nd gen t-cases will chime in.
Not to say, that the 1354 won't work. I'm pretty sure that some have put it in. It's just different from the control trac t-case you have.
And you think I'm joking! I had to fix my 4405 that had up-down rear shaft movement. I thought I had a bad bearing but the case is worn. They have a split housing for the bearing that is anodized to harden it. One end of mine was worn so I ground down the ridge and used some aluminum can as shim material. It won't last forever, but at least the aluminum shim will chew up easily. You might want to live with it. The rear seal is easy to replace and that might keep you going.