4 Wheel Drive/SUVs: 97 Ford Explorer Transfer case, borgwarner, transfer case

Question
We have replaced the transfer case in this vehicle twice and it just went out again.   It makes a really bad whirring noise when slowing down on compression, when it goes out.  I looked it up on the internet and what's happening is the shift rail bore is out of round. The mechanic that fixed it said he put in a brass fitting to stop it from happening again.  I did some research and found that both halves of the transfer case have to be replaced to fix the problem and the mechanic only replaced one half.  Even at that, it is over a $1000 repair.
My question is:  Is there another transfer case that we could replace this one with, it is a BorgWarner 4405, that would not have this continuing problem.  From what I am reading, this is a common problem with this transfer case.  We just had it fixed only 16,000 miles ago.  
We would appreciate any info you have on this. I don't know much about it but it is obviously a problem that is not being fixed properly.  Thank you! Linda

Answer
Linda,

I wish I could tell you that any transfer case would work but I suspect maybe one from a Ranger may work but the choices are limited. There may be some made by EATON and some others but it would be costly. I would see about getting the transfer case replaced but the whole thing not just a partial rebuild. Maybe get a good used unit and build it with the better rebuild kits out there. It may be worth the extra few dollars to build a case that will hold up. the only way to do it right is to build it all at one time and replace the entire transfer case. it will pay off in the end

Matt