Ford 4X4 transfercase Cover
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This is a simple cover designed to fit over where the worm gear box on a borg warner electronic transfercase should be.
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Model information
- Source
- Printables
- Category
- Automotive
- License
- Creative Commons — Attribution — Noncommercial
So the PCM, motor, or switch for your Borg Warner electronic 4X4 goes out in the dead of winter, what do you do? You could go out and spend hundreds of dollars on parts or even a band on diagnoses, parts and labor, or you could grab a 10mm socket, remove four bolts, then grab a set of pliers and manually turn the selector shaft on your transferase.
This is a primitive solution that requires you to crawl under your truck/suv EVERY time you need to change from 2wd to 4hi/4lo. But will it get you moving through the rough terrain again? Yes it will.
The included files are a cover and a 1.8mm gasket. I recommend printing the gasket out of 90a tpu. Being a little softer than 95a makes sure you are keeping water out of your transfercase. I printed the cover out of pla; I don't really see a need for any other material unless you are seeing deep snow/mud, in that case the terrain could break the part especially if it is below freezing. If you are planning to use this for more than a quick fix I would recommend printing out of nylon, polycarbonate, or PETG.
My print settings on my Ender 3 v3 se were
layer height: 2.8
walls: 4
infill: 15% TriHexagonal
print speed: 80mm/s
Use the settings that work best for your printer/material
btw I made the bolt holes have a 10mm fillet and it looks closer to 5mm. If that bothers you I have included the 3mf files as well as the .stl
btw pt2 I have not added the gasket yet. Will update when I do with print settings/alterations if needed
Happy driving!