VSS problem

[Goose57]

hi all I didn’t see a section for transfer cases. I pulled the output sensor out of the rear of my BW4401 transfer case broke off the hold down bolt. Could not get to it so I removed the 6 mounting bolts and rotated the case down to where I could get to it and repair it. Rotated case back up installed case bolts and now the

sensor won’t go back in. It’s bottoming out on the sensor wheel. It’s like the same sensor grew an inch. Am I missing something. The sensor wheel is on the main shaft and spins when I rotate the drive shaft. I can’t see the sensor wheel moving out of place. Is the wheel supposed to be located directly below the sensor or am I crazy. I’m going to try a bore scope to see if I see anything. I hope I don’t have to pull the case. Thanks

 

[dbrannon79]

I know it's a dumb question, but check the depth of the old sensor compared to the new one. the parts house could have given you an incorrect sensor or was possibly boxed wrong.

 

[Goose57]

I know it's a dumb question, but check the depth of the old sensor compared to the new one. the parts house could have given you an incorrect sensor or was possibly boxed wrong.

Same sensor I pulled out. It’s not a new one.

 

[dbrannon79]

My only guess would be if when you rotated the case it might have separated some and things inside are out of alignment. I would need to see a visual of the transfer case and what section you un-bolted and rotated to know more. maybe get an inspection mirror so you can see up in the hole. place the trans in neutral, jack up the wheels so you can turn the drive shaft while looking in the hole making sure the reluctor wheel is in the right spot.

I'm sure others with better knowlage on this t-case will chime in soon.

 

[Will L.]

Pics of how far it is going in please.

 

[dbrannon79]

I am wondering if the gear or reluctor in the t-case is made of plastic. looked online for a diagram to get a mental picture on how you rotated the housing to access the bolt. I would wonder if when you extracted the broken bolt maybe something got jarred loose or out of place in that area.

 

[Goose57]

Thanks guys, here is a step by step that might help.
Broke sensor hold down bolt. Removed sensor
Removed trans. cross member lowered trans. driveshaft still in.
Removed six bolts that hold the case to the auto. trans. adapter.
Trans. in neutral, transfer case not sure, had to take the linkage off to get to the six case bolts.
Rotated case 30-35 deg. Repaired bolt.
Rotated case back up installed six mounting bolts
Original sensor wouldn’t go back in. Could still see the o-ring on the sensor.
I did rotate the drive shaft a couple of times to check if the speedo gear spins.
Yes I’m with you on an alignment issue because of the different angles of the case and drive shaft when I lowered the trans. Also rotating the drive shaft with the case in gear.
Boy that’s a lot of slop on the main transfer case shaft. but the sensor might be that close to the speedo wheel.
I’m going to raise the trans. to original position and see if the sensor goes back in if not spin the wheels w/case in gear to see if the sensor wheel goes back in place.
Will, the sensor goes in up to the o-ring. It just lacks a little bit from being in. I think we may of figured it out by just writing this post and of course your guys input I’ll keep you posted. Thanks.

 

[MrMarty51]

Are You sure that it is just resistance of the O ring inserting back into its bore?
I always give O rings a nice slathering of dielectric grease to help them slip on in.

 

[dbrannon79]

I too think the o-ring might be your issue from getting it in. it's giving you some resistance. try this to verify.... get you a measuring device (small metal ruler is best) pocket screwdriver or something, stick it into the hole and note the depth. then measure the same on the sensor and see where you end up. by doing this will tell you if applying some force on pushing the sensor into the hole will make it contact the gear inside.

Yes the sensor will "almost" touch the gear. it has to be close enough to pickup the movement of the gear, there will be a very tiny air gap between the gear and the sensor probably less than a 1/16 of an inch. then you can slather some lube on the o-ring and push it in without worry of breaking anything. it might take some pushing and twisting action to get it into place.