please help with this t case problem.

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Aug 6, 2012 | 09:59 PM

hunterstroble

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please help with this t case problem.

Hello, I have a 93 f150 4x4, e40d trans and an electric shift borg warner 1356 t case. What's happening is on an uphill take off, especially when turning in 2wd it feels like my tcase is jumping in and out of gear it goes clunk, clunk, clunk in a rotational pattern. When going down steep hills and braking i get grinding, like a gear is trying to be selected. The truck only has 36k on it, but all suspension is like new, all mounts ok, warn premium manual hubs, all drive linke u joints ok, shocks new. I can't find anything wrong. t case fluid clean. I had an aussie locker in the rear but I removed it to make sure that wasn't causing it. Any help would be great, I'm leaning towards a broken fork in the tcase letting a colar move when it shouldn't but i'm no expert at all and don't want to rip apart my tcase for no reason. Thanks! 4x4 works fine in all ranges.

Aug 7, 2012 | 01:13 AM

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If it was a T-Case problem, it should not care if you are turning or going straight.

What I would do is get a permanent marker, and mark the locations/angles of your front u-joints and driveshaft, and see if they are turning while driving. It almost seems to me like your hubs may not be unlocking fully.

Other than that, I know the 1356 case was prone to oil-pump failure, which will tear them up quite quickly.

Aug 7, 2012 | 01:57 AM

hunterstroble

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Sorry I should have been more specific. I get the clunk clunk noise when turning up a hill from a stop or loading it up hill from a stop. It's like something is floating around in there, because i'm putting a big load on it that way. Ive marked the drive shaft as well and it doesn't appear to be turning. Thanks for the reply!

Aug 7, 2012 | 01:58 AM

hunterstroble

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Also I put warn premium manual hubs on it a while ago, whey defenatily are not partially engaged.

Aug 7, 2012 | 06:04 AM

dixie460

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My electric 1356 did that too. At first it would slip (only under load) in 4H or 4L... just like you describe, a rotational-sounding clunk. Then a while later it would start grinding in 2H just driving down the road under light power. Eventually, I pulled into a parking spot at the store and then couldn't reverse out to leave... transfer case wouldn't stay engaged with transmission in reverse. So I drove forward over the curb, and planned on getting my Ranger ready to drive in the next day or so. The next night I am driving in 2H and it loses everything. Just like it was in neutral... well I limped it back and tore it apart. The oil pump busted loose (common problem) and spun around and trashed the shift forks.

This was a great chance to upgrade, so I went to the yard, got a manual 1356 plus linkage, shifter, etc... rebuilt that case with the oil pump mod and bolted it in. Cut a hole in the floor, put shifter in... done.

Now I enjoy a manual 1356, NO soccer-mom pushbuttons here! A rebuilt case and a good, fun learning experience for me.

Aug 7, 2012 | 06:35 PM

hunterstroble

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Thanks for your input. I pulled the tcase out today, it had a couple 1/2" strands of brass in the oil. When i tilted the tcase up and down like i was going up or down a hill there was a clunk each way, and when i tilt it forward or backwards while spinning the input shaft the front drive line yoke randomly rotates 1/3 a turn. I think my problem lies in the tcase, i'll open it up tomarrow. I was just sceptical about opening it up because the truck only has 36k on it and didn't think it would break soo soon. I think the aussie locker killed something in there.