Transfer Case - Mechanical Shift: Other Ford Ranger I

Transfer Case Power Flow

The Borg-Warner 13-54 shift transfer case provides LOW RANGE driving.

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. Using 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.
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. Using the special tool to prevent the flange from turning, install the new washer and the new nut.
7. Connect the driveshaft to the transfer case and install the bolts.
8. Check, and if necessary, fill the transfer case to the correct level with the specified fluid. For additional information, refer to «TRANSFER CASE DRAINING AND FILLING»(ref-204990-S42937071062005111600000) .
9. Lower the vehicle.

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1. Remove the transfer case from the vehicle. For additional information, refer to «TRANSFER CASE»(ref-204990-S02270946012005111600000) .
2. Attach the transfer case to the special tool.
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. Remove the bolts that retain the transfer case cover to the transfer case.
7. Remove the bolts that retain the transfer case to the transfer case cover.
8. Insert a breaker bar between the pry bosses, and separate the transfer case cover from the transfer case. Remove the old sealant. Do not damage the mating surfaces of the aluminum case.
9. Remove the snap ring that retains the bearing in the case.
10. Remove the bearing, spacer and seal. From outside of the case, remove the bearing with a suitable drift. Remove the spacer. From inside the case, remove the seal using a suitable drift.
11. Using the special tools, remove the needle bearing.
12. Remove the following: Remove the shift collar hub. Remove the return spring. Remove the lockup collar and the lockup fork as an assembly. Remove the shift rail.
13. Remove the snap ring, then remove the lockup hub and the sleeve return spring from the lockup collar.
14. Remove the snap ring and the spacer.
15. Remove the drive chain, the driven sprocket, and the drive sprocket as an assembly.
16. Remove the magnet and the oil strainer from the slot in the transfer case.
17. Remove the rear output shaft and the pump assembly as an assembly.
18. Rotate the pump assembly to align the keyway in the cover and the spring pin in the rear output shaft, and separate the pump from the shaft. If it is necessary to install a new spring pin: Measure and record the spring pin height above the output shaft diameter. Remove the spring pin.
19. Holding the bottom of the front output shaft, remove the snap ring. Discard the snap ring if deformed during removal. Remove the front output shaft assembly.
20. Remove the reduction fork assembly and the reduction hub as an assembly.
21. Remove the case from the holding fixture and place it on the bench.
22. Remove the front adapter assembly to case bolts.
23. Remove the front adapter, the input shaft, and the complete carrier as an assembly. Lightly tap around the front adapter to break the seal. Remove the old sealant. Clean the mating surface of the carrier.
24. Using snap ring pliers, expand the tangs of the large snap ring and remove the complete carrier assembly and the input shaft assembly from the front adapter. Expand the tangs of the large snap ring in the main drive gear bearing retainer. With the input shaft against the bench, push the main drive gear bearing retainer down and slide it off the bearing. Lift the input shaft and front planet from the main drive gear bearing retainer.
25. Remove the large snap ring from the front adapter.
26. Using a suitable tool, remove the oil seal from the front adapter. Using a suitable drift, remove from inside the front adapter.
27. Remove the snap ring.
28. Using the special tool, press the bearing from the input shaft.
29. Remove the thrust washer and the input shaft assembly.
30. Disassemble the planetary gear. Remove the snap ring. Remove the thrust plate. Remove the sun gear.
31. Using the special tools and a suitable press, remove the needle bearing and the sleeve bearing from the input shaft.
32. Using a suitable tool, remove the oil seal.
33. Remove the snap ring retaining the bearing to the case.
34. Using the special tools, remove the bearing.
35. Remove the shift fork facings.
36. Remove the set screws.
37. Remove the clip, then pry the shift shaft out of the front case and the shift cam. Remove and discard the O-ring from the shift shaft.
38. Remove the four-wheel drive switch.