2002 Ranger level II 4.0 5spd manual transfer case
 

2002 Ranger level II I am currently on my second transfer case still on factory u joints. Is there a aftermarket upgrade for the manual transfer case?
I'm new to the forums and couldn't find one on transfer cases for the 02,03 level II trucks with the manual setup.

Welcome to the forum

No, as far as I know the only manual transfer case that will work is the Borg Warner 1354 model
Rangers used the BW1354 from 1990 to 2011, in electric shift and manual shift versions, neither were ever a "known" issue, they seemed to last

What's breaking on them?

Transfer case
 

Thanks for the reply. My 1st one split the rear half of the case blew the guts out and the second is about to blow I believe. They are both the 2L54-BA. the first lasted 200k, the second was used unknown mileage I put 20k on it.

That is not a common problem as far as I know

Manual or automatic trans?
Wondering it the transmissions rear shaft is the issue, wild guess
Can't see either drive shaft causing it without crazy vibrations

Its a BW1354 the 2L just means 2002 Ranger, 1L is 2001 Ranger, those number don't matter, just the 1354 does and of course a manual shift

Rear drive shaft connection never changed thru the years
1998-2011 used a propeller joint front drive shaft connection, 1997 and earlier use u-joint(yoke) style

Manual transfer case was not an option after 2002 in Rangers, even on the FX4 Level II

Info here on the Ranger transfer cases: https://therangerstation.com/tech_li...er_cases.shtml

My manual transfer case has 246K miles on it and is working perfectly. Recently, I had to replace the clutch slave cylinder so I decided to take the transfer case apart to make sure everything was in good condition because I was going on an extended off-road trip in the Maze section of Canyonlands in Utah. I found everything in great condition. I considered replacing the bearings but they were still like new. I did replace the seals and chain but really not needed. The old chain had very little stretch but I decide to replace it anyway.

You must be very hard on the transfer case or something in the drivetrain is bad. These transfer cases are pretty sturdy.

BTW, the stock manual transfer cases were available in both 2002 and 2003 but not easy to find.