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1984, 300 L6, smogless, manual 3speed with overdrive.
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Discussion Starter #1
Still investigating but pulled out of the fuel station and had a bang followed by conservative clunks coming from the underside. Limped to my shop got it off the ground and got quite a bit of play in the transfer case between the drive lines. It’s on stands and once a buddy gets here we’re going to run it in gear to narrow down the noise. Took a short video but I don’t use any of the host sites, if someone knows how to upload and is willing to upload one, shoot me a private message with an email and I’ll send it to ya.
 

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1984, 300 L6, smogless, manual 3speed with overdrive.
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715 Posts
Discussion Starter #2
Noise and vibration from said noise IS inside the T Case
 

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1984, 300 L6, smogless, manual 3speed with overdrive.
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715 Posts
Discussion Starter #4
Luckily I have another one but unlucky I haven’t pulled it and don’t know if it’s any good.
So the noise and clunking (not load without a load) happens at 1500-2000 rpms in first with the azz end in the air and is likely something to do with the chain. We’re at dmv registering the Corolla (wife’s new used car) so we got a DD while I fix it the right way the first time, done one too many quick fixes that ended up costing WAY MORE then doing it right the first time.... I’m getting too old for this shiza.
 

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If it is not a Bronco, it's just not worth driving.....
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I don't know what your finances are, but I had my t case completely rebuilt about 18 months ago for $900. That was for parts and labor. I don't have to worry about it anymore so I figure that was a good investment.
 

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1984, 300 L6, smogless, manual 3speed with overdrive.
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715 Posts
Discussion Starter #6
I don't know what your finances are, but I had my t case completely rebuilt about 18 months ago for $900. That was for parts and labor. I don't have to worry about it anymore so I figure that was a good investment.
Being my own mechanic saves a bunch of cheddar on the labor part, being forcibly retired I got plenty of time to work on it, now not anywhere near as fast as I used to be but I can still do it. I’m going to open and inspect the one I got in my parts truck and if it’s good I’ll run with it and rebuild this one down the road once I save up some more lettuce.
 

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1984, 300 L6, smogless, manual 3speed with overdrive.
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715 Posts
Discussion Starter #8

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1984, 300 L6, smogless, manual 3speed with overdrive.
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715 Posts
Discussion Starter #10
Thanks “ backwoods streak” I have another one here in a parts truck just gotta yard it out and give a quick once over to be sure it’s not shot. Once it’s in I’ll pull my apart and see about rebuilding it. I’ll likely clean my manual transmission out and check it since it will be out of the truck as well.
 

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Thanks “ backwoods streak” I have another one here in a parts truck just gotta yard it out and give a quick once over to be sure it’s not shot. Once it’s in I’ll pull my apart and see about rebuilding it. I’ll likely clean my manual transmission out and check it since it will be out of the truck as well.
backwoods streak..........i love it. they dont look complicated at all. i got this one for free from a low mile truck so i was why not i dont need it but im not going to say no ya know.
 

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1984, 300 L6, smogless, manual 3speed with overdrive.
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715 Posts
Discussion Starter #12
Always nice to have spare drivetrain parts in hand fir that one time you pushed to hard or neglected one day too many.
 

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yo! do you have one of those for the 1356? it would just be solid to have as a reference if it ever comes up...
Yo D,
This is closest I have to the 1345 Ford service manual;
Borg Warner 1350 & 1356 Manual & Electronic Shift Transfer Case Service "Article" @ https://www.google.com/url?sa=t&source=web&rct=j&url=http://www.4x4brasil.com.br/forum/attachments/frota-4x4-brasil/428409d1377646985-chegando-mais-uma-f-1000-nossa-efe-1000-a-borg-warner_bw1356.pdf&ved=2ahUKEwiZ2OiM-t3nAhWIHc0KHax3COo4HhAWMAh6BAgGEAE&usg=AOvVaw1iXAKNvpyEECtNhZkVOYQp
FIRST SECTION ADDRESSES electronic case info , so see mechanical info later in "article".

Borg Warner 1356 Manual Transfer Case Rebuild in an 85 by AbandonedBronco @ How to rebuild a BW1356

Borg Warner 1356 Manual Transfer Case Rebuild in an 89 by BLADE262US @ Borg Warner 1356

1356 Manual Shift Rebuild in an 88 F 150 by allfordman @ http://web.archive.org/web/20121031081201/http://www.fullsizebronco.com/forum/showthread.php?t=135334

1356 Manual Shift Rebuild in a 90 by Keith L (TTB Blows, Bling-Bling) @ 1990 Ford Bronco BW1356 pictures, videos, and sounds | SuperMotors.net
"As helirichmentioned, it's about 74 pounds and Keith points out, "This is the oil pump pickup. Black rectangular magnet underneath it slides into a notch in the case" & "Here you see what happens if the shift fork pads wear thru; this 'case had 208k miles on it".

Borg Warner 1356 Manual Transfer Case Rebuild in a 93 F250, (however it's incomplete) by Steve W @ http://web.archive.org/web/20060115121250/http://www.wildercafe.com/fordtech/
See "more to come" but click on each category such as pics (have parts identication, shift fork damage, etc) and more info such as "Removing the transfer case from the truck"

Borg Warner 1356 Manual Transfer Case Rebuild in a 92 F150 by Ken B @ https://www.fourwheeler.com/project-vehicles/129-0406-1992-ford-f150-transfer-case-overhaul/

Borg Warner 1356 Manual Transfer Case Case Wear; "...It is not unusual for the oil pump-retaining bracket to damage the case. Missing figure 4 shows that this particular case has a notch at least half way through the aluminum boss..." There are two ways to fix this problem without replacing the case: one method is to bend the bracket to relocate it to a fresh spot on the case. The second is to rivet or weld a small foot on the end of the bracket that is the same width as the slot in the case, which will prevent further wear. If the bracket is allowed to eat through the case, the oil pump will spin on the shaft; tearing out the feed line and the unit will self-destruct due to lack of pressurized lube. Manually shifted units usually exhibit wear on the selector shaft in two areas . Shaft wear in any form will make the unit disengage or have very sloppy shifting. The star shaped end of the shaft where it mates with the shift cam is also prone to wear. Borg Warner released an updated shift cam with an Allen screw to tighten up the fit and retain the manual lever. Look at the section of the manual lever that rides in the case, which is also subject to wear from dirt and two dissimilar metals in close contact. Always inspect the bore of the case for excessive wear. Figure 6 shows the bore is worn over size and will no longer hold the selector shaft in position. The only way to fix this is to do some machining and sleeve the bore, or to replace the case altogether..." but pics are gone..
Source: by Mike W @ GEARS Magazine - September 2001
¤
Borg Warner 1356 Manual Transfer Case No Movement or Neutral Position Tip/Saver Spacer; "...Many 1987-1995 Ford F series 4x4 trucks and full size Bronco owners with 1356 manual shift transfer cases commonly complain of a "no movement" or an occasional neutral condition. This condition is usually caused by the linkage wearing the transfer case at its point of contact (1356 manual shift models only). Sonnax offers a case saver spacer 36605-01. This case saver spacer goes between the shift selector cam and the case and requires no special tools to install. The spacer moves the cam closer to the shift fork, thus preventing and/or eliminating: 1) one or both shift forks from becoming disengaged from the shift cam, 2) "slop"from the linkage caused by a worn linkage bore in front case half. This item is a specific size/thickness not commonly found in ordinary flat washers. This repair is quick, easy and a lot less expensive than repairing or replacing the case. Model: 36605-01..."
Source: by transmichigan

Borg Warner 1356 Manual Transfer Case Rebuild Tools in a 91; "...50 torx, a 7/16 socket.. 8mm wrench, some snap ring pliers with long teeth, a few small screw drivers, seal puller, punch and hammer, 1.25" socket with impact gun, silicone..." see more info and pics
Source: by DcSkater602

Borg Warner 1356 Manual Transfer Case Rebuild Tools in a 91 by RLVBronco via https://www.fullsizebronco.com/threads/need-help-asap.506020/#post-7226068

Borg Warner 1356 Manual Transfer Case Removal in a 95 by Shadofax (TheJuice, The Juice, Mark Z) @ http://www.fullsizebronco.com/forum/showthread.php?t=66992&highlight=1356+swap+refresh

Borg Warner 1356 Manual Transfer Case DISASSEMBLY AND ASSEMBLY in 96 by FORD @ http://www.diesel-dave.com/vehic/manual/stj/stj77b07.htm
Read more @ http://www.diesel-dave.com/vehic/manual/stj/stjs77bl.htm
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Borg Warner 1356 Electronic Shift Transfer Case DISASSEMBLY AND ASSEMBLY in a 96 by FORD @
Read more @ http://www.diesel-dave.com/vehic/manual/stj/stjs77al.htm

Borg Warner 1356 Electronic Shift Transfer Case Symptom Chart in ab96 by Ford @ http://www.diesel-dave.com/vehic/manual/stj/stj77010.htm

Borg Warner 1356; Four Wheel Drive (4X4) General Information, Operation & Troubleshooting TSB 92-1-8 for Bronco, F Series & Ranger (COMPLETE); Includes Electric Shift On The Fly (ESOF) Troubleshooting & Hub Operation @ http://web.archive.org/web/20130411142814/http://content.chiltonsonline.com/TSB/displayTSBHandler.ashx?assetID=36059&key=6kAUBD5BruOJf/3tgozUqjXM3RdbjcQqW4sVWiE/p2IojfpfKqM07dr61+QAWHtTZr4ceHaQGlj8NylACcNZ4qedMqy4JdYyAXN5akgfkpHUz4aCpJyaaA==

Borg Warner 1356 Electronic Shift Transfer Case Electric Shift Motor Typical Failures & Prevention; "...Most units fail because of water or mud intrusion. Carefully inspect motor boot or protective coverings. Be sure connector seals can keep water and debris out. Check wiring harness and connector. Replace or repair wiring as necessary. After installation, periodically select 4-wheel drive mode to ensure operation when needed..."
Source: by CARDONE®
 
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