BW4406 Transfer Case Ford

Midwest Transmission an automotive parts re-manufacturing and re-building can help you with your BW4406

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Below you will find a detailed list of BW4406 replacement transfer cases and parts that we can supply including: bearing rebuild kits, gaskets and seals, bushings, individual bearings, forks and slider, oil pump, shafts, chain, sprockets and miscellaneous parts. If you need more information or cannot find the parts you need give us a call, if you would like to save money, ask about our good take out parts (GTO), they are inspected and guaranteed.

Midwest transmission has been in the automotive re-manufacturing and rebuilding business for 19 year, shipping completed units world wide. To improve quality Midwest was one of the first companies to include dyno testing of manual transmission prior to shipping as a final step in the quality control process. We specialize in manual transmissions, automatic transmission and transfer cases. We can help with improving performance and conversions. 22 employees shipped over 7500 units last year. Guaranteed quality and correct parts supplied.

We can help you solve your problem and save you some money!

Having issues diagnosing problems with your BW4406 transfer case? We can help free knowledgeable technical support! To speak to a Drive Train Expert or to place an order call toll free 888-824-2012! We have a large inventory of rebuilt BW4406 transfer cases plus Transfer Case parts. Our factory rebuilt re-manufactured Transfer Cases are tested before leaving the factory. Use our online shopping cart, just double click the part number and see additional information, add to cart or proceed to check out. If you need more information or cannot find the parts you need give us a call 888-824-2014.

BW4406 Transfer Case Design and Possible Problems

The BW4406 was manufactured utilizing both manual and electric shift, computer controlled shifting and power distribution between the front and rear differential. Borg Warner manufactured these transfer cases for the Ford Motor Company. The BW4406 was introduced by Ford in the 1996 F150, this transfer case is also used in F250, Ford Excursions and Lincoln Navigators. This unit is similar in design to the BW4405 however the BW4406 has larger components, shafts, chain and sprockets required to support heavier loads, these units are not interchangeable. This Borg Warner 4406 is Torque on Demand, a full-time, chain drive, 2.57:1 ratio, with two piece housings. This unit has a left side drop (front output). Recommended fluid for the BW4406 is automatic transmission fluid ATF.

The BW4406 can show early wear of the shift cam, range hub, shift fork/inserts and input shaft. This failure mode may be manifested by popping or grinding sound in reverse as well as excessive rear yoke end play. Clutch failure is manifested by the unit showing that it’s in 4WD but does not have 4WD. Tire pressure and tire diameter is critical to the BW4406 transfer case all tires should be measured (diameter) and be the same, even uneven tread wear can effect this transfer cases performance and life.

Working on BW4406 Take Advantage of our Expertise

In addition to a rebuilt 12 month warrantied BW4406 transfer cases we offer all parts required to rebuild your unit, we have new parts and we can provide good used takeout parts to save you money! Part identification is some times a problem and knowing just what parts need to be replaced and be an issue, we can help by identification of associated parts that should be replaced when one part fails.

Quality parts, the right parts, first time for your BW4406

We provide a detailed list of rebuilt BW4406 units and parts that are available plus detailed assembly illustration to help you in parts identification and purchasing phase of the rebuild plus assisting you in the rebuilding process. Rebuilt BW4406 transfer cases include all new bearings, gaskets, seal, clutch parts, chains and filters.

Buy parts from Midwest Transmission Center and receive bonus telephone expertise to assist you in diagnosing the problem, parts required and additional phone assistance when you are in the re-assembly process if required. We have a large inventory of rebuilt BW4406 transfer cases plus Transfer Case parts. Our factory rebuilt re-manufactured Transfer Cases are tested before leaving the factory.

Free BW4406 Transfer Case parts illustration

Below we provide a BW4406 parts illustrations to assist you with the correct identification of the parts you need. Select the parts you require from the the list below and give us a call.

Don’t see what you need or require more information on the parts you need give us a call 888-824-2014, if you would like to save money, ask about our good take out parts (GTO), they are inspected and guaranteed.

Need Stronger Parts?

Midwest Transfer Case can Cryogenic Treat any shaft or gear. This cryo treatment will add 30% in component strength. Call 888-824-2012 for a quote.

This information may also be on a paper tag. F57A-CA and F57A-CA are examples of BW4406 assembly number. Please supply this number when purchasing a rebuilt transfer case to insure direct drop in replacement!

Application Model Years
Ford F150 Manual Shift w/o Torque on Demand 1996-1998
Ford F150 Electric Shift w/o Torque on Demand 1996-1998
Ford F150 Electric Shift with Torque on Demand 1997-2003
Ford F150 Exc. Heritage Electric Shift w/o Torque on Demand 2004-2008
Ford F150 AWD 31 Spline Input, 32 Spline Rear Slip 2006-2008
Ford F250 Manual Shift w/o Torque on Demand, Shift on Fly 1996-1998
Ford F250 Electric Shift w/o Torque on Demand 1996-2003
Ford F250 Electric Shift with Torque on Demand 1997-1998
Ford F250 Exc. Heritage Electric Shift w/o Torque on Demand 2004-2008
Ford Expedition Electric Shift with Torque on Demand 1997-1998
Ford Expedition Electric Shift w/o Torque on Demand 1999-2002
Lincoln Navigator Shift with Torque on Demand 1998-2002

Use our online shopping cart, just double click the part number and see additional information, add to cart or proceed to check out.

Rebuilt Tested BW4406 Transfer Cases 12 month warranty

Description Part Number
Ford F150 Manual Shift 1996 UP TCFRD033
Ford F150 Manual Electric 1996 UP TCFRD034

Rebuilt Overhaul Bearing Kits BW4406 Transfer Case

Description Part Number
BW 4406 (Cast 44-06) TRSBK4406

Gaskets, Seal Kits, Seals BW4406 Transfer Case

GASKET & SEAL KITS

Drawing Image Description Part Number
N.I. BW 4406 TSK4406

FILTERS

Drawing Image Description Part Number
012F Pump Screen (Filter) TRS345012
012-1F Pump Hose TRS355012-1

SEALS

Drawing Image Description Part Number
070A Input Seal TRS325080
080A Front Output Seal TRS325080
074A Rear Output Seal 1900-044-013
N.I. Linkage Seal (Rubber Coated) 486072
073A hift Shaft Seal (Electric Motor) 1300-044-001

GASKETS

Drawing Image Description Part Number
N.I. Transfer Case to Adapter Gasket (C-6) 100124
N.I. Transfer Case to Adapter Gasket (4R100, 5R110W) 100124
N.I. Transmission to Adapter Gasket (C-6) TRS36305

Bushings & TH Washers BW4406 Transfer Case

BUSHINGS

Drawing Image Description Part Number
068D Bushing (inside Input Shaft) 1345-127-002
066A Extension Housing Bushing (2.020OD) 10043

WASHERS

Drawing Image Description Part Number
215C Thrust Washer, Clutch Pack (Plastic) TRS345215

Bearings BW4406 Transfer Case

Drawing Image Description Part Number
268F Front Output Shaft Bearing (Front) FC68009
268F Output Shaft Bearing (Rear) 6207N
249D Input Bearing TRS355249
240D Input Bearing (Inner) TRS325249
220C Output Bearing (Rear) (35mm ID) 6207N

Shift Forks & Slider BW4406 Transfer Case

FORKS

Drawing Image Description Part Number
850A Mode Fork (except Torque On Demand) TRS355850
850A Mode Fork (Torque On Demand) TRS355850A
849A Range Fork with pads 4406-596-004
849-1A Range Fork Insert 1356-235-001

HUBS & SLIDERS

Drawing Image Description Part Number
606E Mode Hub TRS355606
606D Range Shift Hub 1356-089-003

Pump & Planet BW4406 Transfer Case

Drawing Image Description Part Number
500E Pump Assembly 4400-508-006
588D Planet (except Torque On Demand) TRS355588
588D Planet (Torque On Demand) TRS355588A

Shafts BW4406 Transfer Case

Drawing Image Description Part Number
672E Main Shaft (except Torque On Demand) TRS355672
672E Main Shaft (Torque On Demand) TRS355672A

Chain & Sprockets BW4406 Transfer Case

Drawing Image Description Part Number
700F Chain (1.00 Wide) 43 Links (Rocker Joint) (Torque On Demand) CL10-066
700F Chain (1.25 Wide) 43 Links (Rocker Joint) (Torque On Demand) CL10-053
700F Chain (1.25 Wide) 43 Links (Round Pins) (except Torque On Demand) CL10-052
805B Drive Sprocket, 1.25 Chain (except Torque On Demand) TRS355805
805B Drive Sprocket, 1.25 Chain (Torque On Demand) TRS355805A
806F Driven Sprocket, 1.25 Chain TRS355806

Miscellaneous Components BW4406 Transfer Case

Drawing Image Description Part Number
N.I. Case Protector Clip – Anti Wear (Prevents Pump Lug Wear in Case) TRS345996
550KC Clutch Pack (includes Housing & 13 Plates) (99-02) TRS355550K
550KC Clutch Pack (includes Housing & 19 Plates) (98-Up Harley) TRS355550AK
550C Coil Assembly TRS345448
448C Housing Coil TRS355448-1
137C Friction & Steel Kit (Double Sided Frictions – Replaces Single Sided) (7 Steels) TRS355137
118C Friction (Double Sided) (Use w/ 355138A) TRS355118
137C Friction (19 Internal Teeth) TRS355118B
137C Friction (31 External Teeth) TRS355118C
138C Steels (Fits Double Sided Frictions) 0.060″THK USE ONLY W/ 355106 (7 EACH) TRS355138A
420A Shift Motor (96-04) TRS355420
420A Shift Motor (05-08) TRS355420A
420A Shift Motor UMM4406
420A Shift Motor 4406-648-002 UMM4407
420A Shift Motor UMM4408

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