Long story short I replaced the transfer case in my 2000 Mazda B3000 4x4 5 speed with a case from a 2008 Mazda B4000 4x4 auto and I have ran into few a issues.

1. Using the new transfer case motor I switched to 4wd and it shifted as it should, but when I tried 4wd low I got the fashing 4wd lights on the dash. I heard the motor turn some but then stopped.

Is there a difference between the two besides the wire to the clutch? I was thinking of just using the original wiring harness and changing the sensor plate thing. Also what is the purpose for the clutch in the 1354?

2. Upon driving my pickup I noticed a high pitched whining sound that didn't change when I pushed in the clutch, put it in neutral or in 4x4. It is only noticeable at speeds above 40 and the pitch increases along with acceleration.

My first thought was the transfer case, but could it possibly be the front drive line isnt seated right?

I have forum searched the hell out of both of these and I can't find an answer.

Any help is greatly appreciated, Thanks!

 

Welcome to the forum

No, no differences both are BW1354 transfer cases

Pull off the shift motor and see if you can manual turn shift rod to 4low, MAKES SURE to block a tire, transfer case NEUTRAL is between 4H and 4L

Look here: https://www.explorerforum.com/forums...-motor.123542/

4th picture is a close up of shift rod, its pointed at 2H(2wd), you can only turn it counter clockwise from 2H, to 4H and to 4L then you have to turn it Clockwise to go back to 4H and 2H

With shift motor off plug in its wires and try shifting it to 4H and 4L to make sure its working

Flashing 4WD lights means the shift motor could turn all the way to the selected position, 2H, 4H, or 4L, so could be transfer case or shift motor issue

Whining is most likely the new(used) transfer case if noise wasn't there before, no, it wouldn't be bad propeller joint, that makes a "clicking" noise

 

So I played around with the shift motor using my old sensor plate. It really wasnt engaging 4 low or 2wd with it adjusted to the maximum in the slots. So i rotated the sensor so that it would actually engage, the motor turned to the position, but then I got the flashing 4x4 lights on the dash. Im guessing the position is beyond what was intended so the computer freaks out.
Has anyone hard wired the shift motor? You could still use the shifter on the dash, but you could turn it a bit further just by adding a switch setup. I played around this is on the bench and the motor only turns about 270 degrees. Roughly the same as the transfer case, but futher than the stock sensor.

 

2000 Mazda or Ranger uses the GEM module to control 4WD

GEM doesn't know degrees, it only sees contact points on the shift motors contact wheel

Yes shift motor should only turn 270deg, it has "stops" to it can only move that far

No, there is no manual electric shift option easily built, you will need to find out why shift motor is not working
The GEM seems to be working OK
Behind the GEM Module is a Double Relay box, this is what powers the shift motor, 12v/ground or ground/12v, like a power window motor, so it turns clockwise or counter-clockwise

So 4WD system has these 4 parts
Switch on the dash, just 3 resistors inside
GEM module, connects to switch, and 5 contact wires on shift motor, also activates the Double Relay box to send 12v/ground or ground/12v to motor part
Double Relay box
Shift motor, gets power from double relay box, has 5 contacts that change with position

Switch is working
GEM is working, because lights do flash
Double relay box is working, if motor does turn in both directions
Shift motor is working but GEM can't tell its position, thats why lights flash

 

Is there a difference between GEM's from 2000 to 2008? Im planning on doing a 5.0 swap in the future so I'm wondering its its really worth the trouble now or just wait till I have a manual transfer case.

 

Yes there is, no GEM in 2008, Ford changed to a SJB(smart junction box) for Body Computer in 2004

GEM = Body computer, 1995-2003 Rangers
SJB = Body computer, 2004-2011 Rangers

And not your problem as far as 4WD system, from your description

And GEM doesn't care about engine size, it just controls cab electrics, i.e. wipers, dome light, door locks, and 4WD if so equipped
So your 2000 GEM would work fine with a V8 under the hood


If you can find one you can put a manual "Shiftser" in place of shift motor, looks like this: https://encrypted-tbn0.gstatic.com/i...wuuOD7wWNiSl&s

Just a **** you pull out and then rotate to the 3 positions manually, spring loaded rod holds it in position
Yes, you have to get under the truck to switch positions

 

soo this is my solution for 4 low. Redneck but it works. Ill keep the motor on for daily driving since the 2wd to 4wd works fine. When I know I'll need 4 low ill just get out, take off the motor and physically crank it in low. This should work until I swap to a 5.0 with the auto tranny and f150 manual transfer case.

I did find a 1354 manual out of a 93 Ranger for $150, but it doesnt have the shift linkage. I know of a 89 ranger with a manual 1350 at a junk yard. Would the linkage off the 89 work on the 93? Also would it bolt up to the stock mounts on the transmission extension housing? And what about the drive shafts with the older transfer case?

I appreciate your help greatly.

 

As far as I know the manual shifter will work on 1350 or 1354 of any year

Your 2000 transmission "should have" the 2 thread holes on drivers side of tail shaft housing, they were gone in 2001 and up models except for Level II models
If you don't have them then you will need one, that's what linkage bolts to

You will need a front drive shaft from 1993 - 1997 Ranger, your 2000 use propeller joint, regular or extended cab don't matter for front drive line
Rear drive line should be the same