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Replacing BW1356 in a 96 auto trans electric shift transfer case

432 Views 11 Replies 4 Participants Last post by  miesk5
So my truck has a loud growling sound on the hwy around 55mph whenever I let off throttle. It improved with a new driveshaft, but did not resolve completely, so I'm thinking it's the T case rear output shaft bearings. I don't have the time or desire to rip the t case apart and rebuild it with new bearings/seals. I'm planning on going this route to circumvent the inevitable oil pump grinding problem.
My only question now is should I keep the electric shift or take this opportunity to switch to a manual shift T case?

The truck is on 4 inch lift, 35's, stock motor, and will not see extreme rock crawling. I'm fine with the current low gear ratio and don't want to fork out $$$ for an Atlas.

Thanks for any opinions.
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So my truck has a loud growling sound on the hwy around 55mph whenever I let off throttle. It improved with a new driveshaft, but did not resolve completely, so I'm thinking it's the T case rear output shaft bearings. I don't have the time or desire to rip the t case apart and rebuild it with new bearings/seals. I'm planning on going this route to circumvent the inevitable oil pump grinding problem.
My only question now is should I keep the electric shift or take this opportunity to switch to a manual shift T case?

The truck is on 4 inch lift, 35's, stock motor, and will not see extreme rock crawling. I'm fine with the current low gear ratio and don't want to fork out $$$ for an Atlas.

Thanks for any opinions.
PS: it's not the rear end - I just had new ring and pinion installed which did not fix the growling sound.
I would pull the rear shaft off and see if the sound continues in front wheel drive? Do some testing before throwing parts at it.
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Yo Snow_Chaser96,
1356 Electric Shift to Manual Shift Swap in a 95
Source: by absent member Shadofax (TheJuice, The Juice, Mark Z) aka The Real Deal, The Man with the Tools, THE MAN, The Real Juice! 😎 👍
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Yo Snow_Chaser96,
1356 Electric Shift to Manual Shift Swap in a 95
Source: by absent member Shadofax (TheJuice, The Juice, Mark Z) aka The Real Deal, The Man with the Tools, THE MAN, The Real Juice! 😎 👍
Wait I resemble that Bronco. The T-Case still works kick ass!
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wileec... WTG!
I would pull the rear shaft off and see if the sound continues in front wheel drive? Do some testing before throwing parts at it.
Trust me I've done some testing. I replaced all the u-joints in the original drive shaft, which was my first decent mechanic work on the truck. It made no difference. I had the tires for balanced because the noise began after I rotated them. KO2s are notoriously hard to balance. Made no difference. Brought it to a better shop with a better machine to do a road force balance. Made no difference. Took it to another shop who told me that there was way too much lash in the pinion gear, so it needed to be replaced, which also was very expensive and made no difference. So I've pretty much narrowed it down to something in the t case.
Yo Snow_Chaser96,
1356 Electric Shift to Manual Shift Swap in a 95
Source: by absent member Shadofax (TheJuice, The Juice, Mark Z) aka The Real Deal, The Man with the Tools, THE MAN, The Real Juice! 😎 👍
Thank you for the link! I think this is something I could probably take on but I'm a pretty inexperienced mechanic. Mainly just curious if it's worth it for light off-road duty. The push button is pretty convenient and I've had no problems with shifting thus far.
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I just went through the same issue, with the same noise n vibration, for bout two years. No one I went to found what the issue was, went to 5 garages. The last one said it was my transfer case. He actually explained, not what the issue was, where it was coming from..

I did not have the money to rebuild the transfer case. My issue included my electronic light switch too, to engage the 4x4 were always at a low dim - still they were on. I did not engage them just they went on every time I started the vehicle and stayed on - both high and low buttons.

I had enough of this electronic stuff and went manual.
I just went through the same issue, with the same noise n vibration, for bout two years. No one I went to found what the issue was, went to 5 garages. The last one said it was my transfer case. He actually explained, not what the issue was, where it was coming from..

I did not have the money to rebuild the transfer case. My issue included my electronic light switch too, to engage the 4x4 were always at a low dim - still they were on. I did not engage them just they went on every time I started the vehicle and stayed on - both high and low buttons.

I had enough of this electronic stuff and went manual.
Thanks for the input. I'm leaning more towards the manual conversion now.
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Parts are out there for the conversion. Tough to find. The toughest I had to find were bolts for the bracket, which the bracket mounts to the transmission and holds the shifter. The next toughest to find was the shift lever/arm going through the floor. I had to find a used transfer case that was in good condition and for the right price. Found mine out of a 94 F250 for 100 bucks with relatively low mileage.

Found my stuff from the good gentlemen on here (big thank you to all who helped me!), craigslist, and Bronco Graveyard had some parts too. Ebay has very few parts for this swap, with one guy selling a package deal on transfer case conversions (round 200 + dollars) on used parts that looked like they went through heck. Yet, you get the bolts needed.

Yes, stuff adds up though I won't deal with the electronic transfer case or hubs. The problems these things gave me :rolleyes:

Stuff for these older vehicles is getting hard to find, if not they already are.

There is a difference inbetween the Broncos and F series trucks transfer case, just to let you know. Something with the front shaft or yoke. Nothing really big to stop going with the switch though.

Yet, that 700 dollar price tag for the electronic transfer case might be the easiest way out. Lots to go over while looking for parts and information.
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Yo,
We were fortunate to purchase our new 96XL that had the Manual 1356.
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