Transfer Case: Service and Repair

BORG-WARNER TYPE 1345 TRANSFER CASE
1. Raise and support vehicle.
2. Drain transfer case fluid, then disconnect four wheel drive indicator switch electrical connector from transfer case.
3. Remove skid plate from frame, if equipped.
4. Disconnect front and rear driveshafts from transfer case.
5. Disconnect speedometer driven gear from transfer case rear bearing retainer.
6. Remove transfer case control lever and shift lever retaining clips and shift rod.
7. Disconnect vent hose from transfer case.
8. Remove heat shield from engine mount bracket and transfer case.
9. Support transfer case, then remove transfer case-to-transmission adapter attaching bolts.
10. Slide transfer case rearward until it clears transmission output shaft, then carefully lower transfer case from vehicle.
11. Reverse procedure to install.

BORG-WARNER TYPE 1356 ELECTRONIC SHIFT & 1356 MANUAL SHIFT TRANSFER CASE
1. Disconnect battery ground cable.
2. Raise and support vehicle.
3. Remove skid plate from frame, if equipped.
4. Drain fluid from transfer case.
5. Disconnect harness electrical connector from transfer case, if equipped.
6. Carefully disconnect front driveshaft from front output shaft yoke.
7. Disconnect rear driveshaft from transfer case rear output shaft yoke.
8. Disconnect speedometer driven gear from transfer case.
9. Disconnect vent hose from mounting bracket. The catalytic converter is located along side the transfer case. Extreme high temperatures generated by the converter.
10. Support transfer case with a suitable jack.
11. Remove transfer case attaching bolts, then slide case assembly rearward from transmission output shaft.
12. Reverse procedure to install.

NEW PROCESS 208 TYPE TRANSFER CASE
1. Raise and support vehicle.
2. Drain transfer case fluid, then disconnect 4 wheel drive indicator switch electrical connector from transfer case.
3. Disconnect speedometer driven gear from transfer case rear bearing retainer.
4. Remove transmission shift lever to transfer case attaching nut.
5. Remove skid plate, if equipped, from frame.
6. Remove heat shield from transfer case.
7. Support transfer case with a suitable jack, then disconnect front and rear driveshafts from output shaft yokes.
8. Remove transfer case to transmission adapter attaching bolts, then carefully lower transfer case from vehicle.
9. Reverse procedure to install.