Mechanical Operation

The Borg-Warner 44-05 transfer case is available in the Explorer (A4WD) vehicle. The transfer case transfers power from the transmission to the rear axle, and also to the front axle when electronically activated.
- Digital transmission range sensor (ground when transmission is in NEUTRAL, open circuit otherwise).
- Start/clutch depressed input (manual transmission only).

Feature outputs:

- 4x4 shift motor relay outputs
- 4LOW cluster indicators (ground when activated open circuit when deactivated)
- Solid state clutch relay (pulse width modulated signal; grounded when relay is on battery potential when relay is off)

In the Auto mode, torque from the transmission is transferred to the input shaft which, in turn, drives the rear output shaft that drives the rear axle assembly. The electromechanical ball ramp clutch assembly drives the drive sprocket after the GEM activates the clutch coil. The drive sprocket turns the drive chain that rotates the front output shaft and the front driveshaft. In the 4x4 High mode, the operation is the same as in the Auto mode, except that the GEM consistently activates the electromechanical ball ramp clutch assembly.
The high-low shift occurs when the reduction shift fork moves the high-low collar to lock the planetary gear set to the output shaft. Then, torque, transmitted through the sun gear, from the input shaft, turns the front planetary gear set assembly. The front planetary gear set assembly, which is now engaged, provides transfer case speed reduction.