Transfer Case Disengages on Hill Climbs

[E350]

I am so sorry to hear. Thank you.

[skumancer]

@E350 how did you end up doing with the BW1356? It’s the only T-case I could get my hands on easily here in Panama, and that’s what’s under my van right now.

[E350]

@skumancer: The fuel tank in my van delaminated and caused a fuel starvation condition which may have overheated the engine. I have a 80 psi compression in cylinder #1. Regardless, I put new injectors in this week and am in the process of flushing the fuel galleys in the heads, etc.

So, what about the transfer case? I will address that after I get the engine running again with a custom welded stainless steel fuel tank, and the low compression diagnosed and addressed.

I think the BW1356 transfer case is a fine transfer case. But in the van application, the motor mounts twist, the frame twists, coasting down hill the rear differential twists against the engine. IMHO all of this twisting causes the shift linkage on the manual BW1356 to lean against the shift forks inside the transfer case.

So what is my planned solution?

Keep the BW1356 but replace the manual shift version with the electronic shift version. My idea is that replacing the shift linkage with electronic shift will eliminate the pressure on the internal shift forks, which wore out twice.

What do you think?

I will report back when I get to it.

[REF]

I was having the same issue of it popping out of gear on me, right at the most inopportune time, crawling up or going down a steep section of trail. Had a rebuild kit installed last winter, not sure of the exact part that was worn or a combination of several, but no more issues, so far. I also recall the shop said the chain seemed a bit stretched from use.

[E350]

@REF Salem-Kroger had me enlarge the shift linkage hole under the shift knob boot before they rebuilt the transfer case under warranty. The little plastic tips on the shift forks inside the T.C. had worn out and were not holding it in gear which worked for awhile then started doing it again. So, the shift linkage pressure on the forks appeared to be a known problem to Salem-Kroger. I am willing to buy a BW1356 electronic shift transfer case to see if it cures the problem (just like the one I have in my two Bronco since 1993 with no problems).

[arctictraveller]

Originally Posted by E350

The little plastic tips on the shift forks inside the T.C. had worn out and were not holding it in gear which worked for awhile then started doing it again. .

Since installing a new planetary gear set that had much less wear on the internal thrust washers, I have far less instances of popping out of low range, but it still occasionally does it. In my case, the plastic shift fork pieces were pretty much like new, so the problem is elsewhere. I did clearance the hole in the floor too, so that's not the issue. One thing that seemed to really help was taking apart the shift linkage, cleaning it up and greasing it well. It now goes into gear much easier and seems to mostly stay there. When I shift to low range, once its in, I'll hold pressure on the shifter while I'll load and unload the transmission a couple times by accelerating and and then lifting the throttle. That seems to assure its fully engaged. I bought a spare 1356 to rebuild in case the current one continued to act up, but so far I haven't needed to replace it, so it sits on the shelf waiting.

[E350]

Hmmm... The BW1356 electronic shift has worked flawlessly in my 1993 Bronco and in my current 1995 Bronco. But the Bronco's are relatively light 1/2 ton vehicles.

arctictraveler could it be that the E350 with the 7.3 is too heavy for the BW1356?

That was my original intuition. Because the BW1356 is not used in the 2002 F Series. Rather, they used the NP 271. I know I would have to change the transmission or at least its tail piece. What would be your ultimate recommendation?

[arctictraveller]

Originally Posted by E350

Rather, they used the NP 271. I know I would have to change the transmission or at least its tail piece. What would be your ultimate recommendation?

Id be inclined to try and figure out whats wrong with your 1356, I am completely satisfied with mine now. My 2001 5.4 is very close in weight to my 2002 7.3 SMB, so i doubt the extra weight of the diesel makes much difference. If you switch to an electric shift, you will need to add the wiring harness, switches panel and electronic control box needed to control it, possibly the tail housing and then weld up the hole in the floor. Before I did all that, I'd make completely sure you have exhausted all other options. I'd check the motor and transmission mounts to be sure it's not moving excessively under heavy load, make sure the shift linkage moves freely and fully engages 4 low, try loading and unloading the drive line when first shifting to low range while pulling back on the lever and if it still pops out, I'd pull it out and measure the free play in the planetary gear set. There is an upgraded aftermarket set that should be better.

https://www.allstategear.com/BW1356-...56-410-004.htm

I saw evidence of excessive play in mine when the center bushing in the planetary was pushed out of position. If you can do this yourself, the cost should be minimal, but no matter what it should be less expensive than converting to electric shift. Best of luck....................

[E350]

Understood and appreciated. I will post up what I do.