Transfer Case: Service and Repair

BORG-WARNER TYPE 1345 TRANSFER CASE
1. Raise and support vehicle.
2. Drain transfer case fluid, then disconnect four wheel drive indicator switch electrical connector from transfer case.
3. Remove skid plate from frame, if equipped.
4. Disconnect front and rear driveshafts from transfer case.
5. Disconnect speedometer driven gear from transfer case rear bearing retainer.
6. Remove transfer case control lever and shift lever retaining clips and shift rod.
7. Disconnect vent hose from transfer case.
8. Remove heat shield from engine mount bracket and transfer case.
9. Support transfer case, then remove transfer case-to-transmission adapter attaching bolts.
10. Slide transfer case rearward until it clears transmission output shaft, then carefully lower transfer case from vehicle.
11. Reverse procedure to install.

BORG-WARNER TYPE 1356 ELECTRONIC SHIFT & 1356 MANUAL SHIFT TRANSFER CASE
1. Disconnect battery ground cable.
2. Raise and support vehicle.
3. Remove skid plate from frame, if equipped.
4. Drain fluid from transfer case.
5. Disconnect harness electrical connector from transfer case, if equipped.
6. Carefully disconnect front driveshaft from front output shaft yoke.
7. Disconnect rear driveshaft from transfer case rear output shaft yoke.
8. Disconnect speedometer driven gear from transfer case.
9. Disconnect vent hose from mounting bracket. The catalytic converter is located along side the transfer case. Extreme high temperatures generated by the converter.
10. Support transfer case with a suitable jack.
11. Remove transfer case attaching bolts, then slide case assembly rearward from transmission output shaft.
12. Reverse procedure to install.

*** UPDATED BY TSB #87-24-15

The All "Touch Drive" service replacement electric shift motor on 4x4 vehicles may bind at the neck because of insufficient shaft-to-motor housing clearance during the replacement procedure.

If service is required, use the appropriate Light Truck Shop Manual procedures with the following supplemental service procedure to prevent the binding condition.

1. Remove all traces of RTV gasket sealant from motor housing base and transfer case mounting boss.
2. Slightly loosen the two (2) nuts that attach the slotted support bracket to the end of motor housing.

NOTE: Do not loosen the (2) nuts or studs that attach motor end cap to motor housing.

3. Apply non-acidic RTV gasket sealant to motor housing base and assembly to transfer case using the appropriate Light Truck Shop Manual procedure.
4. Install three (3) screws along with speed sensor (7K470) bracket and tighten to 6-8 lbs. ft. (8-11 Nm).
5. Holding slotted support bracket tight against motor housing end, secure bracket to transfer case torquing screw with lockwasher to 6-8 lbs. ft. (8-11 Nm).
6. Retighten the two (2) nuts that attach slotted support bracket to end of motor to 2-2.5 lbs. ft. (2-3 Nm).
7. Follow remaining assembly procedure shown in the appropriate Light Truck Shop Manual.

NEW PROCESS 208 TYPE TRANSFER CASE
1. Raise and support vehicle.
2. Drain transfer case fluid, then disconnect 4 wheel drive indicator switch electrical connector from transfer case.
3. Disconnect speedometer driven gear from transfer case rear bearing retainer.
4. Remove transmission shift lever to transfer case attaching nut.
5. Remove skid plate, if equipped, from frame.
6. Remove heat shield from transfer case.
7. Support transfer case with a suitable jack, then disconnect front and rear driveshafts from output shaft yokes.
8. Remove transfer case to transmission adapter attaching bolts, then carefully lower transfer case from vehicle.
9. Reverse procedure to install.