The BW 4406 transfer case was introduced in 1996 for a variety of Ford vehicles, including Ford F-150 and F-250 models with a GVWR less than 7,200 lbs. The transfer case was offered as either a part time or full time torque-on-demand unit, making it suitable for Ford's AWD Expedition model. The BW 4407 is the heavy duty alternative to the 4406, used in pickups with a GVWR greater than 8,500 lbs. Both transfer cases feature similar low range ratios, the BW 4407's being slightly shorter. The transfer case model can easily be identified, like all BorgWarner cases, by the metal ID tag bolted to the transfer case.
The stronger BW 4407 was available with a PTO (power take off) option, allowing it to be used with hydraulic accessories. It was designed specifically to be used with the Ford E4OD automatic and ZF manual transmissions. Due to the chain drives, both the BW 4406 and BW 4407 require ATF for lubrication. Behind automatic transmissions, the transfer case and transmission lubrication systems are isolated from one another, meaning that the transfer case and transmission fluids must be changed independently.
BorgWarner BW4406 Specs
| Manufacturer | BorgWarner | |
| Applications | Select 1996 - 2003 Ford F150/F250 pickups & Ford Expedition. < 7,200 lbs GVWR |
|
| Case | Cast aluminum | |
| Drive Type | Chain drive, manual & electronic shift versions. Available as part time or fill time, torque-on-demand | |
| Gear Ratios | High Range | 1.00 : 1 (direct drive) |
| Low Range | 2.64 : 1 | |
| Fluid Type/Spec | Automatic transmission fluid (ATF), 4 pint (1.9 liter) capacity | |
| Weight | 98 lbs dry | |
| Identification | Metal ID tag bolted to case - see figure below | |
BorgWarner BW4407 Specs
| Manufacturer | BorgWarner | |
| Applications | 1996 - 1998 Ford F250/F350 pickups, > 8,500 lbs GVWR |
|
| Case | Magnesium | |
| Drive Type | Chain drive, part time, PTO available for F350, manual & electronic shift versions | |
| Gear Ratios | High Range | 1.00 : 1 (direct drive) |
| Low Range | 2.69 : 1 | |
| Fluid Type/Spec | Automatic transmission fluid (ATF), 2 liter capacity | |
| Identification | Metal ID tag bolted to case - see figure below | |
BorgWarner transfer case identification tag location & breakdown
