14 GEARS January / February 2006

The purpose of this article is to troubleshoot the electrical components of the transfer case

system used on mid 1980s through 1996 vehicles. These vehicles use a separate transfer case control module. On later 4WD systems, which are con-trolled by a GEM module, see the May 2001 GEARS magazine article Another GEM of a Problem, written by Lance Wiggins. Since there are many ver-sions of this system, please refer any mechanical transfer case or hub con-cerns to an appropriate repair data base or repair manual.

WARNING: The following items must be noted and corrected before attempting to operate or troubleshoot the 4WD system.

• The vehicle must be in good mechanical order

• You must be familiar with the correct operation of the spe-cific system

• The vehicle must have four matched tires and correct tire pressure

• Both drive shafts must be straight with good U-joints

• Both hubs must lock and unlock correctly (if applica-ble)

• The transfer case must be filled with the correct fluid

For many years, Ford vehicles with electronic shifted 4WD used a small external electric motor to rotate a cam inside the transfer case. By rotating the cam, a shift fork moves back and forth to engage 2HI, 4HI or 4LO. Be aware that some models use automatic locking hubs while others use manual locking hubs.

Some of these vehicles have a Touch Shift or Shift on the Fly, which allows the driver to select 2HI or 4HI while in motion. To accomplish this, a magnetic clutch is energized to hold the 4WD sprocket. The transfer case control module then rotates the internal cam with the electric motor to lock the 4WD sprocket. Once the transfer case is in 4HI, the magnetic clutch is

released.On some systems, if the driver

selects 4L while driving in 2HI, the transfer case control module will shift the transfer case to 4HI while the vehi-cle is moving. When the vehicle comes to a complete stop and the transmission gear selector is placed in Neutral, the transfer case control module will then select 4LO. On other systems, if the driver selects 4L while driving in 2HI, the 4LO indicator will flash until the vehicle comes to a complete stop and the transmission is put in Neutral. Then it will select 4LO without first going to 4HI.

Itʼs best to troubleshoot the system based on the symptoms. Based on one of six symptoms, you should be able to identify the problem and repair the vehicle.

SYMPTOM 1 – System seems off, nothing happens, lights off

Try unplugging the 8-pin square connector of the transfer case control module for a few minutes (figure 1). Reconnect it and see if the transfer

Troubleshooting the Troubleshooting the Borg-Warner 1354 & Borg-Warner 1354 & 1356 Transfer Case 1356 Transfer Case Control ModuleControl Module

For many years, Ford vehicles with electronic shifted 4WD used a small external electric motor to rotate a cam inside the

transfer case.

by Dave Skora

Figure 1: Eight Pin Square Connector

dave-skora.indd 14dave-skora.indd 14 12/28/05 2:02:54 PM12/28/05 2:02:54 PM

Automatic Drive P.O. Box 440Bellows Falls, VT 05101-0440 USA800-843-2600 • 802-463-9722 • F: 802-463-4059www.sonnax.com • info@sonnax.com

©2006 Sonnax

D E S I G N E D T O S A V ETM

Receive up to $100 per tool kit in manufacturer rebates when you purchase any of these Sonnax tools for your shop between January 1 and March 31, 2006.

Rebuilding has its rewards

To receive your rebate, please submit a copy of your invoice and the attached questionnaire.Send to Sonnax, Attn: Rebate Program. Payment will be made in the form of a Visa® debit card.

Please allow 4 to 6 weeks for payment.

How many bays in your shop: 1-5: _____ 6-10: _____ 11 or more : _____ Number of rebuilders:__________

I receive my Sonnax® information from: Direct Sonnax mailing: ____ Distributor sales representatives: _____ Technical organizations: ____

Do you currently own any Sonnax tooling? Y/N If NO why?__________________________________________________________________

Have you used Sonnax valve solutions in the past? Y/N If NO why?___________________________________________________________

Name:____________________________ Title:________________________ Company Name:________________________________________

Address:_______________________________________________________________________________________________________________

City/State/Zip/Country:__________________________________________________________________________________________________

Phone:________________________________ Fax:________________________________ E-mail:_____________________________________

37947-TL11 ........$100

F-22771A-TL7 ....$100

95200-TL ............. $40

F-84596-TL ..........$40

FM-01KA ..............$40

T36605-04 ............$40

22771-TL ..............$20

33000-TL ..............$20

33886-TL ..............$20

36948-TL ..............$20

37947-TL5 ............$20

37947-TL9 ............$20

37947-TL33 ..........$20

56361-TL ..............$20

73840-MTL...........$20

73840-RTL ...........$20

74846-TL ..............$20

76948-TL4 ............$20

76991-TL ..............$20

77754-TL ..............$20

84754-TL3 ........... $20

85991-TL ..............$20

89010-TL ..............$20

96201-TL ..............$20

F-22771-TL ..........$20

F-33000-TL ..........$20

F-73840-TL ......... $20

F-119940-TL3 ......$20

F-119940-TL6 ......$20

F-119940-TL7 ......$20

F-119940-TL8 ......$20

T36605-03 ............$20

VB-FIX ..................$20

33886-TL2 ............$10

36833-TL ..............$10

36946-TL2 ............$10

56833-TL ..............$10

56947-TL ..............$10

72854-TL ............. $10

72854-TL2 ............$10

73840-BTL............$10

74846-TL5 ............$10

77754-R2..............$10

77754-SERV .........$10

77964-RM2 ......... $10

77968-RM.............$10

84754-TL2 ............$10

84754-TL4 ............$10

96201-TL2 ............$10

96201-TL3 ............$10

96206-TL ..............$10

96206-TL2 ............$10

Part # Rebate AmountPart # Rebate Amount Part # Rebate Amount Part # Rebate Amount Part # Rebate Amount

See Transmission Specialties™ Volume 6 for a complete line

of Sonnax® solutions.

sonnax-ad.indd 15sonnax-ad.indd 15 12/21/05 11:49:42 AM12/21/05 11:49:42 AM

16 GEARS January / February 2006

case control module resets itself. If not, continue with the following tests. Use the PIN VOLTAGE CHART to check

voltage and circuits (figure 2). Make sure the transfer case control module has power and ground. Check fuse 17

(most vehicles) for power to the LO and HI indicator bulbs. Disconnect the 8-pin flat connector (figure 3). Measure

Figure 3: Eight Pin Flat Connector

It’s best to trou-bleshoot the system based on the symp-toms. Based on one

of six symptoms, you should be able

to identify the problem and

repair the vehicle.

Troubleshooting the Borg-Warner 1354 & 1356 Transfer Case Control Module

5 PIN FLAT CONNECTORPin Function Wire Color Spec

1 Shift control switch feed Wht/lt blu 5 Volts

5 volts in 4HI2 4x4 input from dash (4HI switch) Dk blu

0 volts all others

5 volts in 4LO3 4x4 input from dash (4LO switch) Org/lt blu

0 volts all others

B+ 4LO light off4 4LO indicator light Brn/wht

0 volts 4LO light on

B+ 4HI light off5 4HI indicator light Gray

0 volts 4HI light on

8 PIN FLAT CONNECTORPin Function Wire Color Spec

(M/T) Neutral safety switch Red/lt blu 12 volts in N1

(A/T) Neutral safety switch Red/wht 12 volts in N

2 Speed sensor (+) Lt grn

3 Speed sensor (-) Lt blu225-275 ohms between pins 2 & 3

0 volts in 2HI & 4LO4 Switch plate Pink/Y

12 volts in 4HI

12 volts in 2HI & 4HI5 Switch plate Wht

0 volts in 4LO

0 volts in 2HI & 4HI6 Switch plate Brn/wht

12 volts in 4LO

0 volts in 4HI7 Switch plate Org/wht

12 volts in 2HI & 4LO

8 Switch plate ground Y/wht Always less than 0.10 volt

8 PIN SQUARE CONNECTORPin Function Wire Color Spec

1 N/A

2 Ground Blk Less than 0.10 volt

3 Ground Blk or Blk/org Less than 0.10 volt

4 Electric motor Org See testing SYMTOM-1

5 Magnetic clutch Brn 1.5-5.0 ohms

6 Electric motor Y See testing SYMTOM-1

7 Ignition R/Y or Wht/Ppl Key on 12 volts

8 Battery voltage Bk/W or DG/LG 12 volts

Figure 2: Pin Voltage Chart

dave-skora.indd 16dave-skora.indd 16 12/28/05 2:03:20 PM12/28/05 2:03:20 PM

ALL OTHER OFF-THE-SHELF ATF ADDITIVES FALL IN THESE CATEGORIES…

World’s FinestLubricants! A W I T H

•LUBEGARD’s SYNTHETIC Liquid Wax Esters(LXE) are more heat stable than any productever sold. LUBEGARD is so heat stable, itoutperforms it’s nearest competitor by over100 degrees Fahrenheit!

•LUBEGARD’s SYNTHETIC Liquid WaxEsters (LXE) and its derivatives arefunctional molecules made in chemicalreactors. Other aftermarket additivemanufacturers (mix masters) blendstandard production chemicals, oftenmisrepresenting various claims oftechnological breakthroughs.

•International Lubricants Inc., holds over 80U.S. and foreign patents on new innovativesynthetic molecular technologies.

•LUBEGARD is the ONLY product of its kind that isUsed, Endorsed, Designated and Approvedby multiple OEM’s (Original EquipmentManufacturers). Other aftermarket transmission

products may make similar claims, but none haveever produced a single technical service bulletinnaming their product! LUBEGARD has eight OEMservice bulletins!

•LUBEGARD was selected by OEM’s becauseInternational Lubricants, Inc., is one of a fewexclusive research and development manufacturers who produce their own uniquesynthetic materials.

•LUBEGARD is the #1 product used by professionalautomotive technicians around the world.

•LUBEGARD With LXE Is The ONLY ProductThat Effectively Transfers HEAT!

•Only LUBEGARD Reduces Excessive Heat UpTo 40°F!For Every 10 degrees of heat reduced you double thelife of the fluid! For every 20 degrees of heat reducedyou double the life of the transmission!

Are among the most reactive, corrosive anddestructive chemical additives in the markettoday. The Federal Trade Commission hasbrought a number of these companies to legalaction due to false performance claims. Whenchlorinated paraffins break down, they canform acids, which attack bearing materialsand components. Acids also degrade the ATFadditive packages and form sludge.

INTERNATIONAL LUBRICANTS, INC.7930 Occidental South • Seattle, WA 98108 • PO Box 24743 • Seattle, WA 98124206-762-5343 • 800-333-LUBE (5823) • Fax: 206-762-7989 www.Lubegard.com

Seal Swellers are designed to penetrate, soften and swellgaskets, o-rings and seals, expanding their volume andstopping leaks. The seal materials are actually physicallydamaged and this will cause them to fail completely.Professional rebuilders do not use seal swellers orsolvents for short-term fixes that will eventually causecomebacks.Solvents dissolve and change the fluids behavior. Solventsare unstable in the presence of heat and reduce thethermal stability of the ATF they are added to.

Used, Endorsed,Designated & Approvedby Multiple Major CarManufacturers, (OEM’s)HERE’S WHY!

This additive group is based on active zinc andphosphorous. ZDDP is neither a new or cutting edgetechnology. These inexpensive additives weredeveloped in the 1950’s and have been usedextensively in most conventional formulations sincethen. It can act as a sludge builder. Sludge and heatkills transmissions. The newest generation of GMDEXRON®/MERCON® (factory fill), MERCON®V aswell as Chrysler Mopar® ATF +4® are completelyZinc free.

ILI, known for their LUBEGARD® brand name, is the #1 product usedand recommended in the professional transmission repair industry. It’sLXE® (liquid wax ester) Technology is also the only of its kind to be used,endorsed, designated and approved by multiple OEM’s (car manufacturers). Prior to the endangered species act in 1972,sperm whale oil and its derivatives were used as additives in virtually all automotive lubricants because of its exceptionallubricity (wetting agent) and heat resistance. Generally, automatic transmission fluids were never changed because of thesperm whale oil derivatives. Once its use was banned, the rate of failures rose from under 1,000,000 to a staggering numberof over 8,000,000 by 1975! A direct synthetic replacement was invented by ILI in conjunction with Dr. Philip Landis, a highlydistinguished research chemist who headed the Mobil Oil Applied Lubrication Research Group. This solution is the patentedLXE Technology which has been proven to out perform the sperm whale oil additives.

➡

LXE

LUBEGARD Is The Only

Product Of Its Kind To Be

Used, Endorsed, Designated

and Approved By Multiple

Major Original Equipment

Manufacturers (OEM's)!

SEAL SWELLERS/SOLVENTSSEAL SWELLERS/SOLVENTSCHLORINATED PARAFFINSCHLORINATED PARAFFINS ZINC COMPOUNDS (ZDDP)ZINC COMPOUNDS (ZDDP)

lubegard-xtra-53.indd 17lubegard-xtra-53.indd 17 12/21/05 11:00:13 AM12/21/05 11:00:13 AM

18 GEARS January / February 2006

the speed sensor resistance at connec-tor pins 2 and 3. The resistance with the vehicle stopped should be 225-275 ohms. Reconnect the 8-pin plug.

Disconnect the 8-pin square con-nector. Measure the magnetic clutch resistance between the harness side

pin 5 and ground. It should be 1.5-5.0 ohms. With the transfer case in 2WD and the engine off, apply 12 volts to the harness side of pin 5 for a second. The clutch should click to lock the 4WD sprocket.

At the 8-pin square connector, apply 12 volts to pin 4 and ground pin 6 for about one second (figure 3). The electric motor should rotate clockwise stopping at the 4L position. Reverse the polarity and the electric motor should rotate counterclockwise stopping at the 2H position. Reconnect the 8-pin square connector.

NOTE: It is common for the elec-tric motor to wear out, fail from being submerged in water, or if the internal stops have broken off.

With all connectors plugged in, turn the ignition on. Back probe pin 1 of the 5-pin flat connector (figure 4). There should be five volts. Operate the 4HI and 4LO switches. Make sure the correct pin at the transfer case control module has five volts (see the PIN VOLTAGE CHART). Using a jumper wire, back probe and ground pin 4

of the 5-pin flat connector. The 4LO indicator light should come on. Back probe and ground pin 5 of the 5-pin flat connector. The 4HI indicator should come on.

To check the shift plate switches inside the electrical motor, make sure all connectors are plugged into the transfer case control module. Turn the ignition on and place the gear selec-tor in Park or Neutral. Back probe the negative lead of your voltmeter to pin 8 of the 8-pin flat connector. Back probe the positive lead of your voltmeter to pin 4. Select each range and check for the correct voltage pattern of the switch plate input (see the PIN VOLTAGE TEST CHART).

You may have to operate the vehi-cle to engage each electric motor posi-tion. Repeat this test for the remaining pins 5, 6 and 7. If the electric motor wonʼt move, try energizing it with voltage as previously described. If the voltage does not match the chart, either the wiring is bad or the electric motor assembly is bad.

Troubleshooting the Borg-Warner 1354 & 1356 Transfer Case Control Module

If the electric motor won’t move, try

energizing it with voltage as previ-

ously described. If the voltage does

not match the chart, either the wiring is bad or the electric motor assembly is

bad.

dave-skora.indd 18dave-skora.indd 18 1/5/06 3:47:33 PM1/5/06 3:47:33 PM

GEARS January / February 2006 19

SYMPTOM 2 – Wonʼt shift to 4LO

Make sure the speed sensor circuit is good. Make sure the module is get-ting a neutral signal from the MLPS or TR switch. If no problems were found during SYMPTOM 1 tests, replace the module.

SYMPTOM 3 - Transfer case control module clicking

Make sure the plate switches test good. See the PIN VOLTAGE TEST CHART. If the plate switch circuits are good, replace or repair the electric motor.

SYMPTOM 4 - Shifts by itself on startup

This may be caused by the plate switches indicating the electric motor is between positions, the motor is bad, or someone touched the shift button when the ignition was in the accessory position.

SYMPTOM 5 - Position lights display wrong range

Disconnect the module. See the PIN VOLTAGE CHART for the 4LO and 4HI indicator light circuits. Turn

the ignition on. Using a jumper, jump the appropriate pins at the harness to ground. If each light works correctly, replace the module. If not, check the light circuits for shorts, opens or no feed voltage.

SYMPTOM 6 - Rough 2HI to 4HI shift

This symptom is usually caused by a weak magnetic clutch or internal

transfer case problems.As you can see, this system is

very simple to understand and diag-nose. When symptoms like these occur, following the six-symptom diagnostic procedures will help speed things up.

Figure 4: Five Pin Flat Connector

dave-skora.indd 19dave-skora.indd 19 1/5/06 3:48:59 PM1/5/06 3:48:59 PM