Tranfer Case chain
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Tuned
Joined: Jul 2004
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From: Delaware
Tranfer Case chain
.I just bought yet another Bronco, a 1991 5.8FI with E4OD transmission this time. Like I really needed a third one. The guy I bought it from said he thought it had a bad transmission as it didn't back up and made an awful noise. I believe it's the chain in the transfer case as it makes a clicking noise when driving. Sometimes reverse works fine, sometimes it's the chain slipping making the awful clatter. What model transfer case should this year have so I can round up the parts needed to repair it. This has the manual four wheel drive lever in the floor. How much different is this transfer case compared to my others with the push button four wheel drive? Other than removing the case and disassembling it, what am I in for to repair this? Any help is appreciated
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From: N. Gwinnett Co. Georgia
Near as I can tell a 13-56 manual case. Can you put the Bronco on a tire lift and safely get underneath to listen to the cause of the noise? Friend had the same type noise you're indicating and it was combination of motor mount/transmission mount/u-joint all trashed making that type of noise. Only happened in reverse as far as the shudder and the clicking was in the forward gears.
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Tuned
Joined: Jul 2004
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From: Delaware
Tex, I had the guy I bought it from drive around in a parking lot while I stood outside and listened and the noise certainly comes from the transfer case area. It's no U joint or other minor problem. When it slips, while in reverse, it's a MAJOR noise. It is so bad you can't hardly pull it back into neutral fast enough and the chain slipping noise continues while in neutral for another short time. I'm sure it's the chain slipping. I've been a mechanic all my life but I've never done a transfer case other than to remove/install one. I need to know what I'm in for to fix it.
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From: N. Gwinnett Co. Georgia
Roger that. Sounds like a gear drive issue on the chain though. The chain will wear due to that. It's much simpler inside than say, a Borg-Warner T10 or other manual tranny. Basically transfers the power, via chain, from one end of the case to the other when engaged. I've seen some apart and the engagement mechanism, wait a minute, was roached and clattered like hades. Just may be your problem. No major tools you probably don't have that I saw. Once the engagement synch was gone it slid in and out of contact and made an awful racket or clicked ALL the time, I wonder.... Oh, by the time John got it taken down (I hauled his pony to the shop on our 18' trailer) it was so gone he got a salvage yard case and bolted it in much more reasonably than a rebuild. The chain had eaten into the case a bit and he didn't trust it. Bet you could find a case fairly reasonably and just change out. Good luck.
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Tuned
Joined: Jul 2004
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From: Delaware
OK, I've found it's a Borg Warner 1356 manual shift transfer case. Since I've never had one apart before, is it possible to remove the rear drive shaft and work on it in the Bronco or does it have to be removed? Any adjustments that can be made? Any help or hints on how to fix it will be greatly appreciated.
Last edited by gov2mod; Feb 6, 2005 at 10:11 AM.
Fleet Mechanic
Joined: Nov 2003
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From: North Dakota
I had went through my t-case a couple of months ago. If you look in my gallery you can see some pics of it opened and what not. The chain does not move in 2-wheel drive so I can not see how that could be the prob? Does it only do it in 4wheel?
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Tuned
Joined: Jul 2004
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From: Delaware
It does it in two wheel drive. If the chain doesn't engage in two wheel drive then how does the power from the transmission get to the rear drive shaft since the transmission goes in the left front of the transfer case and the rear drive shaft exits the right rear of the transfer case?
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Posting Guru
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From: N. Gwinnett Co. Georgia
13-56
Well gov2mod, I'd think that maybe you could do it if anybody could as you seem to have some improvise, adapt, and overcome to you. I think it may be possible. As to the 2wd/4wd the reason John's crashed was the selector for 4wd, we think. It didn't matter what was engaged, it was broken and not working. Rear driveshaft should exit in a plane with the transmission and the front drive shaft from the lower left forward side of the t-case.
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Thread Starter
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Tuned
Joined: Jul 2004
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From: Delaware
No, actually on this transfer case the front and rear driveshafts exit the transfer case all the way over on the right side, front and back, inline with each other. The transfer case is mounted directly to the rear of the transmission and it enters the transfer case on the front left side.
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Tuned
Joined: Jul 2004
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From: Delaware
Disregard my last two posts, I was taking someone else's word on how it was laid out. The transmission and rear drive shaft are in line and the front drive shaft exits out the left front. As we all know if you want something done right, do it your self. Now with that straight, back to the problem. Sometimes it goes right in reverse and backs up. Sometimes when you put it in reverse it does not move at all but makes a horrendous grinding sound. I mean terrible. You can't hardly move it into neutral fast enough and the noise will continue for a period of 10-20 seconds even after it's in neutral. It is definately something not connecting the way it should. It doesn't happen in drive. When it did it last, I put in drive, moved a little, back in reverse, big noise. Back in drive, back in reverse, it made no noise and backed up. Could it be the shaft from the transmission into the transfer case slipping in one direction?
Last edited by gov2mod; Feb 6, 2005 at 01:40 PM.
Fleet Mechanic
Joined: Nov 2003
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From: North Dakota
Ya, no big deal, I used to think the same thing until I craked my case open and found out myself. It is a possibility that the shaft could be worn down but I have never heard of that, mainly because there is not enough horsepower or torque present to cause such failure. I would tend to think that it could be a problem with the E4OD. I am not familiar with those trannys at all, but from all of the problems I have heard about them it could be a tranny problem. I had a 90 Bronco with a 351 and a e4od. When I would put it reverse it would clunk so hard! I sold it because I did not have more money to dump in the e4od and I was putting a new engine in my 88 at the time. I had a friend that had a Bronco with an e4od and it was making a similar noise in reverse and finally it just would not go into reverse. He still drives it but he can not backup!
Last edited by kameronth; Feb 6, 2005 at 02:55 PM.
Thread Starter
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Tuned
Joined: Jul 2004
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From: Delaware
What is the major diffence between the Borg Warner 1356 with manual shift and the one with electric shift? Can you remove the electric shift and make it a manual shift? I was just wondering as my AOD transmission in my 1990 Bronco is slipping in Drive and Overdrive so I could "borrow" the transfer case from it if it would work.
Posting Guru
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From: N. Gwinnett Co. Georgia
The transfer case has nothing at all to do with the E4od slipping. Is it slipping significantly? If not try an anti-shudder additive. There are a ton out there. Our mechanic uses the Lucas brand, FYI, not an endorsement.
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Tuned
Joined: Jul 2004
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From: Delaware
Tex, the E4OD isn't slipping. It works all of the time in forward gears although there is sometimes a clicking sound. In reverse it either works fine, no slipping, or it doesn't move whatsover and makes a noise like you threw a handfull of wrenches into an open transmission. I mean horrible. It sounds like you were trying to put a standard transmission into gear but you didnt' bother using the clutch. I don't want to pull the transfer case apart for nothing but it sounds like that's where the noise comes from.
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From: N. Gwinnett Co. Georgia
I'm gonna say go with the evidence and check the t-case. Everything points to it. Got the '90 Bronco info mixed up with this issue. I hate it, but if you've inspected the undercarriage and driven it yourself, seems like it might be the culprit. Have you drained the fluid and looked for metal, should be a fair amount if that's the issue?