I know diagnosing problems over the net must be like predicting winning lotto numbers, but here goes....

1990 Bronco XLT 5 speed manual t-case (BW 1356???)

Just replaced my rear slip yoke after snapping the u-joints. Had to creep home in FWD and noticed the t-case would pop out of gear occassionally, assumed it was due to no load on the rear shaft. Now that she's back together, the thing is stuck in 4 Lo, the shifter moves through all the motions (4x4 light indicates correct position, with exception of 4Lo, I'm assuming the light is burnt out, but the 4x4 light is still on) it feels like it's moving some internals in the T-Case, but she's in 4Lo. Now the weird thing is that she'll still pop out sometimes into neutral, and if I shift up to 4Hi or 2wd, no change, she stays in neutral. If I slam her back down into 4Lo she'll go back into that gear. I'd be happy if I could get it to stay stuck in 2wd until I can afford to do a rebuild on it, or would it be cheaper to swap in another t-case, I can get them around here for like $50 - $75 (conditions unknown) Anybody have any ideas as to whats wrong and what I should to do rectify the situation? I've owned the truck for 6 month's, driven it maybe a total of 6 days, and it's really draining the bank account, the list of brand new parts seems to be growing, Radiator, waterpump, fan, rad hoses, serpentine belt timing cover, coil wires and plugs, all the fluids, battery, yadda yadda yadda. I really like the truck, but it spends more time on the back of a tow truck then on the road.

 

The BW1356 is just a borg warner part time transfer case that was used around 85-96.
The only help I can give is a suggestion that you have it in 4 lo, back up 10 feet or so, and put the trannsmition in neutral, press the brake pedal, and try to shift into another gear(2hi).

 

thanks for the tip, I had tried that with no change in situation.

 

were can you get t-cases for 50-75 dollars. I won a tcase on ebay and got burned but i still need the tcase.

 

I live in British Columbia Canada, they're fairly common to get up here.

 

call your local junkyards and check F-series trucks and Broncos from about 85-96. I got a t case from a junkyard for about $50 and it was in great shape. They're out there.

 

I dont know about the $50.00-$75.00 range but I just had to put in a new trans in my 1982 and I went to a trans rebuild shop and asked if they ever get any transfercases and they said yes and even had a New Process 208 like mine. They wanted $600.00 for a rebuilt one but hey thats not that bad.I bought a fully remanufactured motor for$949.00 and a rebuilt SROD trans for $750.00.

 

Sounds like it's a bit premature to start talking about another transfer case. Have you checked the linkages to be sure that 4 hi and 2 hi links are still connected?

 

yup I sure did.

 

I just went through the same problem you described your shift forks on the inside of the tc are broken If you are mechanicaly inclined you can order the replacement parts and put the the tc back together yourself.

PS order a whole new oil pump assy when you work on the shift forks and went you open the oil pump (sandwhich style pump) CAREFULLY look at how the oil scrapers are positioned if you get them backwards youll be calling up the gear supplier again for new parts. the book was not very clear as to how they are put in.

Good luck

 

I agree. Fork, fork pads or range sliders. Rebuild it or replace it. Here's a site that will give some indication of what it would cost to rebuild it.

http://www.drivetrain.com/transferca...-Warner%201356

 

Thanks for the advice guys, I'll give it a whirl!