Electronic Shift

Fig. 16a Borg-Warner 1350 Transfer Case (Electronic Shift):

Fig. 16b Borg-Warner 1350 Transfer Case (Electronic Shift):

Fig. 17 Transfer Case Wire Connector:

Fig. 18 Electric Shift Motor Assembly:

1. Remove transfer case drain plug with a 3/8 drive ratchet, and drain fluid.
2. Remove rear output shaft flange by removing nut, washer and rubber seal from output shaft, Fig. 16.
3. For GSB ``IRH'' option vehicles, remove front output shaft yoke by removing locknut, washer and rubber seal from output shaft.
4. Remove wire connector assembly from mounting bracket on rear cover. If required, remove two bolts and remove bracket.
5. Form a small hook from at the end of a paper clip and remove locking sleeve from wire connector with paper clip, Fig. 17. Be careful not to damage locking sleeve.
6. Remove brown wire from center of connector. If required, also remove green and blue wires.
7. Remove speed sensor, bracket retaining bolt and bracket.
8. Remove remaining three bolts retaining motor to rear cover and remove motor. Note position of triangular shaft extending out of rear cover and triangular slot in the motor, Fig. 18. Motor is serviced as a complete assembly. Do not remove screws that secure rear cover to motor gear housing.
9. Remove nine bolts that retain front case to rear cover. Insert a 1/2 breaker bar between pry bosses and separate front case from rear cover. Remove all traces of RTV gasket sealant from mating cover surfaces.
10. If speedometer drive gear is to be replaced, first remove output shaft rear oil seal, then remove speedometer drive gear.
11. If rear output shaft bearing requires replacing, remove internal snap ring that retains bearing in bore. From outside of case, drive out bearing with output shaft bearing replacer, T83T-7127-A and driver handle T80T-4000-W or equivalents.
12. If required, remove front output shaft caged needle bearing from rear cover with puller collect tool No. D80L-100-S and impact slide hammer tool No. T50T-100-A or equivalents.
13. Remove nuts retaining clutch coil assembly to rear cover. Pull assembly, along with O-rings and brown wire, from cover.
14. Remove 2W-4W shift fork spring from boss on fork.
15. Remove clutch housing assembly from output shaft. If required, remove snap ring and clutch housing from shift collar hub.

Fig. 19 2W-4W Lock-Up And Shift Fork Removal:

16. Remove 2W-4W lock-up assembly and 2W-4W shift fork as an assembly, Fig. 19. Then remove shift fork from lock-up assembly. If required, compress slotted end of shaft and remove roller bushing and shaft from 2W-4W shift fork.
17. Pull out shift rail.
18. If disassembly of 2W-4W lock-up assembly is required, remove internal snap ring and pull lock-up hub and spring from lock-up collar.
19. Remove helical cam assembly from front case. If required, remove helical cam, torsion spring and sleeve from shaft.
20. Remove external snap ring and thrust washer that retains driven sprocket to front output shaft.
21. Remove chain driven sprocket and drive sprocket as an assembly.
22. Remove collector magnet from notch in front of case bottom, then remove output shaft and oil pump as an assembly.
23. If oil pump assembly is required, remove four bolts from pump body. Note position of pump front cover, body, pins, spring, rear cover and pump retainer as removed.
24. Remove high-low range shift fork and hub as an assembly. If required, compress slotted end of shaft and remove roller bushing and shaft.
25. Turn front case cover and remove six bolts retaining mounting adapter to front case. Remove mounting adapter, input shaft and planetary gear set as an assembly.
26. Expand tangs of large snap rings in mounting adapter. With input shaft against a bench, push adapter down and slide adapter off ball bearing. Lift input shaft and planetary gear set from adapter.
27. If required, remove oil seal from mounting adapter with seal remover tool No. 1175-AC and slide hammer tool No. T505-100-A or equivalents.
28. Remove internal snap ring from planetary carrier and separate planetary gear set from input shaft assembly.
29. Remove external snap ring from input shaft. Place input shaft assembly in a vise and remove ball bearing with split-type bearing puller No. D79L-4621-A. Remove thrust washer, thrust plate and sun gear off input shaft.
30. If required, remove ring gear from front case half using a press. Note relationship of serrations to chamfered pilot during removal.
31. If required, remove external snap ring and remove ball bearing retainer and clip from case. It may be necessary to tap on face of front output shaft and U-joint assembly with a plastic hammer. Remove internal snap ring and drive ball bearing out of retainer with bearing replacer tool No. T83T-7127-A and driver handle Tool No. T80T-4000-W or equivalent.
32. Remove front output shaft and U-joint assembly from front case. If required, remove oil seal with seal remover tool No. 1175-AC, and impact slide hammer tool No. T50T-100-A or equivalent. If required, remove internal snap ring and drive ball bearing out of front case bore using appropriate driver.
33. Remove internal snap rings that retain bearings in the shaft.

Fig. 20 Front Output Shaft Bearing Removal:

34. Position U-joint tool No. T74P-4635-C or equivalent over shaft ears and press bearing out, Fig. 20. If bearing cannot be pressed all the way out, remove it with a vise grip or channel lock pliers.
35. Position U-joint tool on spider in order to remove opposite bearing, then repeat procedure until all bearings are removed.