92' Ford Ranger XLT with 2.9 V6.
You may have seen my recent posting about changing my rear axle assembly. My transfer case is also worn out. Not surprising since it has 492,000 miles.
I have no need for 4WD and the electronic shift motor has been broke for years.

The transfer case is always spinning in 2WD correct? It seems very expensive to install a remanufactured transfer case just for 2WD. Is there a cheaper part approved for my make/model/year to be a place holder for driveshaft in 2WD?

 

The 4x2 Bronco II's came with a "dummy" transfer case. It was basically an empty transfer case housing with just a shaft to connect the transmission to the slip yoke. Might be a BW1350, but I can't remember for sure. Not sure what your truck has, but it might be an option for you, if you can find one.

 

It's possible you could use the transmission tail housing and drive shaft off a 2wd ranger, but I'm not sure if there will be electrical issues with VSS location.

 

Transfer case front drive chain and gears are not spinning unless front hubs are Locked, so its just a straight thru shaft, same as a tail shaft on 2WD transmission

If main shaft bearings in transfer case are shot and you want an alternative, then you need to get a 2WD transmission and drive shaft

A4LD, if automatic, from a 1989-1994 2WD 2.9l OR 4.0l, these engines have the same block so same bellhousing bolt pattern
1995 Ranger got different trans with more solenoids, 4R55E

If manual trans then an M5OD-R1 from a 1988 to 1997 2WD 2.9l OR 4.0l
2WD Manual trans has speedometer cable hook up thru 1997

And you also need the 2WD drive shaft matching your body length

 

My truck has the A4LD transmission. And it uses the Borg-Warner BW1354 transfer case. Installing a 2WD transmission would be too expensive. I wonder if I could just rebuild my old BW1354 transfer case empty with only the shaft, bearings...etc. I think they sell rebuild kits for this.

 

No reason you couldn't do that, but the main shaft is were everything is, only other parts inside are the chain and front drive shaft yoke

BW1354 rebuild kit without chain is under $100

Chain runs about $50

 

Interesting. I'll look into this. I'll see if I can find a diagram or photo of what the BW1354 looks like inside. And I'll see if there is a Youtube video for this. I hope the kits also include a new shaft for inside the case too.

 

There are quite a few BW1350/1354 rebuild videos

 

Ok. Cool. I do all my own repairs on my 92' Ranger. Does this transfer case rebuild sound like something I can do myself?

 

Yes, you can, basic tools unless a bearing decides to be tough to change

 

Ok. Thanks Ron. I'll look into it. It's not something I would do without written instructions. I don't know if anything like that is available.

 

Ford's 1992 Ranger Shop Manual set should have transfer case details, seen here: https://www.ebay.ca/itm/164826254883...IAAOSwh3RggKeA

Check local library they often have Shop manuals, for the BW1354 1990-2000 Ranger manual would have correct procedures

 

Ok. I'll check the public library.

I talked to a seller that stocks the BW1354 rebuild kits. I asked him what do I do if the shaft is scored and needs replacing. He agreed that could be an issue and his company does not sell the shaft.

 

Have you looked on car-part.com

You can use a 1990-1997 BW1354 from any 4x4 Ranger or Mazda B-series, or Explorer, these all have the speedometer hookups
Used BW1354s are not a risky gamble

 

Right. Yes. I've already had 2 or 3 people suggest car-part.com. I'll check it out.

 

I did not forget about you guys. I am currently browsing a few junkyards in my area to see what they have to offer.

 

I don't like dealing with these junkyards. A couple days ago, I thought I purchased a BW1354. They would not allow me to examine the part first. I had to pay for it ahead of time.
Then I went to pick up the part on Thursday. Before I left their lot, I looked at the tag with the model number. There was no number 1354 on it. They sold me the wrong one.............a BW4406 instead. I immediately got a refund. What a fiasco. I'll keep looking

 

I just finished a complete rear axle assembly and drum brake overhaul earlier this month. I'll have to put off this transfer case replacement till the fall.
I'll be turning 500,000 miles this year with the original transfer case. So it definitely needs to be replaced and it shows signs of advanced wear.

 

The rear axle assembly replacement eliminated ALL abnormal driveline sounds. The transfer case still needs to be replaced at some point due to excessive shaft end play.
So this is on the backburner for now.
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