Install a new chain in a tansfer case

[34ford]

Have a 97 all wheel drive ford explorer with 180,800 miles on it. There is a clunk in the transfer case upon hard acceleration which is the chain jumping on the sprocket. This has been comfrimed by the tranny guy. He wants up to and not over $1,300 to rebuild it.  I'm wondering how hard is it to just replace the chain in one of these. I've built motors, set up rearends and am mechnical incllined. Would it cause problems to put a new chain in if the sockets are in reasonable shape.  Junk yard guy has one from a rollover wreck in the yard for $325. Any information would be appericated. Have not did any research on the web yet for rebuilt or other information.

thanks

bob

[wayne petty]

have you checked the tech section at the lower right corner of this page..


http://www.therangerstation.com/tech_library/index.php


actually the id section is here... looks like you might have one of three..

http://www.therangerstation.com/tech_library/TransferCases.html

BW1354
   1991-1995    (Electric Shift) with speedo hole, with sensor hole fixed front output yoke
   1991-1995    All (manual shift)

   1995-1998    (Electric Shift)rear circular flange front fixed yoke with speedo hole, w/o sensor hole
   
1998-2000    (Electric Shift)rear circular flange front cup yoke w/o speedo hole, w/o sensor hole

   2001-2002    Electric shift, rear circular flange, front cup yoke w/o speedo hole, w/o sensor hole BW without coil

BW4403
   1999-2001    AWD

BW4404
   1996-1997    Viscous drive,  front and rear flat circular flange with speedo hole

   1997    Viscous drive, front cup yoke, rear flat circular flange w/speedo hole

   1998    Viscous drive, front cup yoke, rear flat circular flange w/o speedo hole

BW4405
   1995-1997    (Electric Shift) circular rear flange, fixed front yoke torque on demand, front & rear sensor, speedo hole

   1996-1998    (Electric Shift)front cup yoke, rear circular flange torque on demand, front and rear speed sensor, speedo hole

   1998-2001    (Electric Shift)(front & rear speed sensor) torque on demand, front cup yoke rear circular flange w/o speedo hole

BW4410   2002-2004    Viscous drive, front cup yoke, rear circular flange. w/o speedo hole

BW4411   2002-2004    (Electric Shift)front cup yoke, rear circular flange, w/o speedo hole



there are a LOT of ford explorers in the junk yards..

you can remove the transfer case in probably an hour.. rear drive shaft..

front drive shaft.. shift linkage or electrical connectors..   5 or 6 bolts from the adaptor to the transfer case...  then lift it down...

there are a few.. on 2 wheel drive versions that were straight through... no gear train or chains..   just in case you want to convert to 2 wheel drive..

if you can identify exactly which one you have.. i will try to find info on how to rebuild it...