Overhaul - Borg Warner 1359 Ford Bronco II I

DESCRIPTION

The Borg-Warner 1359 transfer case contains an input and output shaft connected together by a coupling sleeve. This transfer case is used on 2WD applications only.

LUBRICATION

Input and output shaft assemblies are supported by prelubricated, sealed bearings which require no periodic lubrication. DO NOT fill case with lubricant.

Removal

1. Raise and support vehicle. Remove rear drive shaft from transfer case output shaft flange. Support drive shaft.
2. Remove output shaft flange 30 mm lock nut, steel washer and rubber seal from rear of output shaft. Remove flange. Pry oil seal from rear output shaft rear cover bore with screwdriver.

Installation

1. Ensure output shaft rear cover bore is free from nicks and burrs. Fill speedometer gear cavity with multipurpose grease. Coat oil seal with grease.
2. Drive oil seal squarely into bore with Seal Installer (T83T-7065-B). Install remaining parts. Tighten lock nut to specification.

1. Raise and support vehicle. Disconnect rear drive shaft from transfer case output shaft flange. Disconnect speedometer cable.
2. Support transfer case with transmission jack. Remove 5 transfer case-to-transmission bolts. Slide transfer case rearward off transmission output shaft. Lower transfer case from vehicle.

1. Clean old gasket material from transfer case-to-transmission mating surface. Install new gasket. Position transfer case so transmission output shaft aligns with splined transfer case input shaft.
2. Slide transfer case onto transmission. Install and tighten 5 retaining bolts in specified sequence. (Scheme 28) Install remaining components.

Scheme 28

Disassembly

1. Remove rear output shaft 30 mm lock nut, flat steel washer, rubber seal and flange. Pry out rear output shaft oil seal with screwdriver. (Scheme 29)
2. Remove nine 15 mm bolts which retain front case to rear cover. Insert a 1/2" breaker bar between pry bosses and separate front case and rear cover. Remove speedometer drive gear from rear output shaft cover.
3. Remove rear spacer collar from rear output shaft. Remove rear output shaft and snap ring assembly by lifting it out of locking coupling and input shaft in front case.
4. Remove locking coupling from externally splined end of input shaft assembly.
5. Remove rear output shaft ball bearing snap ring from rear cover. Drive output shaft ball bearing out using Output Shaft Bearing Replacer (T83T-7025-B).
6. Remove six 15 mm bolts retaining mounting adapter to front case. Remove mounting adapter, input shaft bearing, thrust plate and sleeve as an assembly.
7. Remove output shaft pilot needle bearing and bushing from rear bore of input shaft. Expand tangs of large snap ring in mounting adapter. Remove input shaft from mounting adapter.
8. Remove external snap ring from input shaft. Press ball bearing from input shaft. Lift thrust plate and sleeve off input shaft. Remove seal from mounting adapter with Seal Remover (T77248-A) and slide hammer.

Scheme 29

1. Before reassembly, lubricate all parts with Dexron II ATF. Drive input shaft oil seal into bore of mounting adapter.
2. Install spacer sleeve between thrust plate plate and external splines of input shaft. Install thrust plate onto input shaft with stepped face toward front of transfer case.
3. Press ball bearing onto input shaft with snap ring groove facing toward rear of transfer case. Install external snap ring.
4. Place tanged snap ring in mounting adapter groove. Expand tanged snap ring and install input shaft assembly in adapter. Tap face of input shaft against wood block to ensure snap ring is seated.
5. Install mounting adapter on front case. Install and tighten 6 retaining bolts.
6. Install locking compound on external splines of input shaft assembly. Install output shaft and snap ring assembly into locking compound and input shaft. External splines of output shaft must engage internal splines of locking coupling and input shaft.
7. Install spacer hub onto output shaft with square teeth side facing toward front of transfer case.
8. Drive rear output shaft ball bearing in rear cover bore. Install internal snap ring that retains ball bearing in cover.
9. Install speedometer drive gear into rear cover. Pack speedometer gear cavity in rear cover with grease. Install output shaft rear oil seal into rear cover bore.
10. Position rear cover onto front case. Install and tighten 9 bolts. Install rear flange, rubber seal, flat steel washer and lock nut on output shaft. Tighten lock nut.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS