Assistance Please: Borg Warner 1356 removal

[Skitter302]

Hey guys,

I've been looking around and I'm unable to find any detailed information on how to remove my bad T-case. I have Borg Warner 1356 in my 1989 Bronco XLT Manual shift. Its binding when the front is engaged and now I need to pull it out. I'm wondering if you guys can help me out by linking me to a Video or series of pictures on the removal of a case. I have looked and I can find videos on how to take a 1356 apart, but their is barley anything else. I have also looked in my Chilton's book and it list the basic steps, not much detail.

Thanks in advance for you guy's help.

 

[miesk5]

yo Skitter302,

Maybe someone else has pics or vids for you; here is what I have;

See my site @ http://www.broncolinks.com/index.php?index=70

for LINKs to:

1356 Manual Shift Removal in a 91; "...tools required to remove / reintall case

Source: by DcSkater602

the cases are very simple and you can figure out how to remove everything as you go along...reinstall is very easy

tools required to remove / reintall case from the truck... 12mm 12point wrench for the rear driveshaft bolts, 13mm for the 6 bolts that hold the case in, w/e wrench for your front driveshaft, a small screwdriver for conncetors and vss wire retaining clip removal

in a 96, but similar to your 89 by Ford

.....

Removal w/2 pics in a 03 F 150 4x4; similar;

and

...

TRANSFER CASE 1356 Electric Shift General Information, Operation & Troubleshooting, Parts Break-Out Diagrams, Rebuild, etc. in a 92 Explorer, but Similar; Wiring Diagrams for Bronco, Explorer, etc. Source: by Ford

Removal

1) Raise vehicle on hoist. Remove skid plate (if equipped).

Remove drain plug and drain transfer case lubricant. Disconnect 4WD

indicator switch wire at transfer case. On electric shift models,

disconnect wiring harness plug at rear of transfer case. On manual and

electric shift models, disconnect front drive shaft from axle input

yoke.

2) Loosen clamp retaining front drive shaft boot to transfer

case. Pull drive shaft and front boot assembly out of transfer case

front output shaft. Disconnect rear drive shaft from transfer case

output yoke. Disconnect speedometer driven gear from case rear cover.

3) Disconnect vent hose from control lever. Loosen or remove

large and small bolts retaining shifter to extension housing. Pull on

control lever until bushing slides off transfer case shift lever pin.

If necessary, unscrew shift lever from control lever. Remove heat

shield from transfer case.

4) Support transfer case with a transmission jack. Remove

transfer case-to-transmission bolts. Slide transfer case rearward off

transmission, and lower case from vehicle. Remove gasket from between

transfer case and extension housing.

Installation

1) Install new transfer case-to-extension housing gasket.

Position transfer case so input shaft splines align with transmission

output shaft. Slide case forward onto transmission output shaft and

dowel pin.

2) Install transfer case-to-transmission bolts. Tighten bolts

evenly and in a clockwise sequence from locating pin, as viewed from

front of vehicle.

3) Remove jack from transfer case. Install heat shield on

transfer case. Move control lever until bushing is in position over

transfer case shift lever pin. Install both attaching bolts by hand.

Tighten large bolt retaining shifter to extension housing first.

Tighten small bolt next.

4) Install vent assembly so White marking on hose is in

position in notch on shifter. Vent hose should be positioned so that

upper end of hose is about 2" above top of shifter and inside shift

boot. Connect speedometer gear to transfer case rear cover.

TRANSFER CASE - BORG-WARNER 5) Connect rear drive shaft to transfer case output shaft

yoke. Clean transfer case front output shaft female splines. Apply a

small amount of multipurpose grease to splines. Insert front drive

shaft male spline.

6) Connect front drive shaft to axle input yoke and tighten

bolts. Push drive shaft boot to engage external groove on transfer

case front output shaft. Secure boot with clamp. Connect 4WD indicator

switch wire connector at transfer case. On electric shift models, plug

in motor wire connectors.

7) Install drain plug and tighten. Fill transfer case with

Dexron II ATF. Install fill plug. Install skid plate to frame and

tighten bolts, if used.

Fig. 10: Electric Shift Harness Connector

Courtesy of Ford Motor Co.

--

With M5OD in a 90

by RFR (Mark B)/>/> at http://web.archive.org/web/20040512085612/http://rfr.htmlplanet.com/bronco/journal/journal_page16.html

The first logical step was to get the truck up on ramps and safe-guarded with jack stands. Removing the transmission involved first removing the transfer case. This required removal (just to get the darn thing out of the way) the front drive shaft and removal of the rear drive shaft (wired out of the way). Any wiring needed to be disconnected as well. In my truck I also needed to remove the speedometer cable and pinion from the rear of the transfer case. This was only a one bolt task. I used my floor jack with a custom built platform to remove the transfer case from the transmission adapter. Once the shift linkages were disconnected and the bolts from the transmission adapter removed, the 74 lb Borg Warner transfer case was lowered and removed from the truck.

 

[Skitter302]

WOW, You really have some sweet resources miesk5. Thank you for the reply! Looks like I have more info to read though and this also gives me a idea on where to look for more stuff. /emoticons/[email protected] 2x" width="20" height="20" /> IF any one else has anything they want to add, Post it up!

 

[Skitter302]

Wow I actually posted this topic back in January O_O Feels like last month...

Just wanted to add a Bronco Update, On Saturday (7/13/13) I replaced the T-case. It was a lot of work and the hardest part was putting in the "new" Case. I went out this morning to test everything and it all worked great.

Today is a happy day!