Transfer Case - Automatic Shift: Other Ford Ranger I

Electronic Shift Control System

Four-wheel drive mode is selected using a rotary switch located on the instrument panel. With the vehicle ignition on, the on-board controller verifies and matches the shift motor position to the switch.

To shift in and out of 4WD low, three conditions must be met

1. The automatic transmission must be in NEUTRAL or the manual clutch depressed.
2. The brake must be applied.
3. The vehicle speed must be less than 5 km/h (3 MPH).

Electric Shift Motor

The motor assembly and connector, mounted externally on the transfer case cover, drives an electric shift cam which moves the lockup fork and the reduction fork assembly to the selected vehicle drive position. An integral position sensor provides information to the electronic module on the current motor position.

Digital Transmission Range (DTR) Sensor

The DTR sensor is located on the outside of the transmission at the manual lever. The DTR sensor completes the start circuit in PARK and NEUTRAL, the reversing lamp circuit in REVERSE and the neutral sense circuit (4x4 only) in NEUTRAL. The DTR sensor also sends a digital output signal to the Powertrain Control Module (PCM) indicating the position of the manual lever (P,R,N,D,2,1).

Clutch Pedal Position Switch

The clutch pedal position switch is located on the clutch pedal bracket. On vehicles equipped with manual transmissions, the clutch pedal must be fully depressed with the vehicle stopped in order to make a range shift from 4H to 4L, or from 4L to 4H.

Brake Switch

The brake switch is located on the brake pedal. The brake must be depressed in order to make a range shift from 4WD high to 4WD low or back.

Rotary Control Switch

The rotary control switch is located on the instrument panel. The switch consists of a knob with a night time illuminated pointer. The switch is used to select 2WD, 4WD high or 4WD low. The dash indicator light will illuminate when the 4WD high or low position is engaged.

Control Module, Electronic

The electronic control module controls the operation of the transfer case in response to the inputs from the brake switch, the DTR sensor, the clutch interlock switch, and the motor assembly through the actuation of the rotary control switch.

Transfer Case Power Flow

The Borg-Warner 13-54 Electric Shift Transfer Case provides LOW RANGE driving. This system has no selectable neutral.

In the 4x2 mode, torque from the transmission is transferred to the input shaft assembly, which in turn drives the rear output shaft that drives the rear axle assembly.

The 2W-4W shift is accomplished through the shifting of the lockup collar that engages the drive sprocket on the rear output shaft. The drive sprocket turns the drive chain, which turns the driven sprocket on the front output shaft assembly. The front output shaft assembly then drives the front driveshaft.

The high-low shift is accomplished when the reduction fork assembly moves the reduction hub to engage the complete carrier assembly to the output shaft. Torque from the input shaft assembly is then transmitted through the sun gear, which then turns the complete carrier assembly. The complete carrier assembly, now engaged to the output shaft, provides the reduction.

The unit is lubricated by a gerotor oil pump assembly that pumps the oil through the bore in the rear output shaft.

REFER to FOUR-WHEEL DRIVE SYSTEMS .

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1. Remove the drain plug and drain the fluid. Clean and install the drain plug after fluid is drained.
2. Remove the fill plug and fill the transfer case. The fluid must be just below the fill plug hole. Because you can reach the fluid with a finger does not mean the fluid is at the correct level. Make sure the fluid is level with the filler opening for the correct fluid level. The total transfer case fill capacity is 1.2 liter (2.5 pints).
3. Install the fill plug.

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1. With the vehicle in NEUTRAL, raise and support the vehicle.
2. Disconnect the rear driveshaft from the transfer case and position the driveshaft aside. Index-mark the front flange on the driveshaft and the flange on the transfer case. Remove and discard the four bolts. Disconnect the driveshaft from the transfer case and position the driveshaft aside.
3. Use the special tool to prevent the flange from turning. Remove and discard the nut and the washer.
4. Using a suitable puller, remove the flange.
5. Remove the oil seal if it remains on the rear output shaft.
6. Using the special tool, remove the oil seal.

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1. Clean the seal mounting surface.
2. Using the special tool, install the new oil seal.
3. Position the flange on the rear output shaft. If necessary, reseat the oil seal in the flange.
4. Install a new oil seal in the flange.
5. Using the special tool, install the flange. Tighten the nut on the special tool to 54 Nm (40 lb-ft) to seat the flange on the shaft.
6. Use the special tool to prevent the flange from turning. Install a new washer and a new nut.
7. Connect the driveshaft to the transfer case and install the bolts.
8. Check the transfer case fluid level. If necessary, fill the transfer case to the correct level with the specified fluid. For additional information, refer to «TRANSFER CASE DRAINING & FILLING»(ref-204989-S38483925202005111600000) .
9. Lower the vehicle.

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1. Raise and support the vehicle.
2. Disconnect the transfer case harness connector.
3. Remove the two bolts retaining the harness to the motor assembly and connector.
4. Remove the rear bolt.
5. Remove the remaining front bolt and the motor assembly and connector. Note the position of the triangular shaft extending out of the transfer case cover.
6. Clean the mating surfaces of the motor and the transfer case cover.
7. To install, reverse the removal procedure. Apply a thin coat of Ultra Silicone Sealant F7TZ-19554-AA or equivalent to the motor housing base.

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1. Raise the vehicle on a hoist.
2. Remove the four bolts and the damper.