Manual Shift

Fig. 10 Borg-Warner 1350 Transfer Case (Manual Shift):

1. Drain lubricant front transfer case, then remove four-wheel indicator switch and the breather vent plug, Fig. 10.
2. Remove rear output yoke, then the front case to rear cover attaching bolts.
3. Separate front case from rear cover, then remove all gasket material from mating surface.
4. If speedometer drive gear or ball bearing assembly is to be replaced, remove output shaft oil seal. The seal can be removed from inside of rear cover with a brass drift and hammer, or from outside by bending and pulling the oil seal lip. Discard oil seal, then remove speedometer drive gear assembly.
5. Remove rear output shaft ball bearing snap ring, then the bearing using tool Nos. T80L-100-S and T50T-100-A or equivalents.
6. Remove front output shaft caged needle bearing from rear cover using tool Nos. T80L-100-S and T50T-100-A or equivalents.
7. Remove 2W-4W shift fork spring from rear cover.

Fig. 11 Shift Coller Hub And 2W-4W Lock-up And Shift Fork Assemblies.:

Fig. 12 2W-4W Lock-up Assembly:

Fig. 13 High-Low Shift Assembly, Output Shaft And Collector Magnet:

Fig. 14 Mounting Adapter Assembly:

8. Remove shift collar hub from output shaft, then the 2W-4W lock-up assembly and shift fork as an assembly, Fig. 11.
9. Remove shift fork from lock-up assembly, Fig. 11. If necessary, remove external clip, then roller bushing assembly from shift fork.
10. Remove internal snap ring from lock-up collar, then remove lock-up hub and spring from collar, Fig. 12.
11. Remove snap ring and thrust washer retaining drive sprocket to front output shaft, then remove chain, driven sprocket and drive sprocket as an assembly, Fig. 11. Remove magnet from front case, Fig. 13.
12. Remove output shaft and oil pump as an assembly.
13. Remove shift rail, high-low range shift fork and high-low shift hub from front case, Fig. 13.
14. Invert front case and remove mounting adapter retaining bolts, then remove mounting adapter, input shaft and planetary gear set as an assembly, Fig. 14.
15. Press ring gear from front case. Note position of ring gear for assembly reference.
16. Remove planetary gear set and input shaft from mounting adapter by expanding large snap ring under adapter and plying under gear set with screwdriver, Fig. 14.
17. Remove oil seal from mounting adapter using tool Nos. 1175-AC and T50T-100-A or equivalents.
18. Remove internal snap ring from planetary carrier, then remove planetary gear set from input shaft assembly, Fig. 14.
19. Remove external snap ring from input shaft, then install input shaft assembly in a press and remove ball bearing using tool No. D79L-4621-A or equivalent.
20. Remove thrust washer, thrust plate and sun gear from input shaft, Fig. 14.
21. Place shift lever in Two Wheel High (2WH) position, then make an alignment mark on outside of front case at the shift lever.
22. Remove set screws from front case and shift cam, then invert front case and remove external clip.
23. Remove shift lever from front case and shift cam. Remove O-ring from second groove in shift lever shaft.
24. Remove detent plunger and compression spring from inside of front case.
25. Remove internal snap ring and ball bearing retainer from front case. Remove bearing from retainer using tool Nos. T83T-7925-B and T80T-4000-W or equivalents.

Fig. 15 Front Output Shaft Assembly:

26. Remove front output shaft and U-joint assembly from front case. Remove oil seal, then the internal snap ring and ball bearing from case, Fig. 15.
27. Install front output shaft and U-joint assembly in a soft jawed vise, then remove internal snap rings which retain bearings in shaft.
28. Press bearing out of front output shaft using tool No. T74P-4635-C or equivalent. Reposition tool on spider and remove opposite bearing. Repeat procedure for remaining bearings.