Borg Warner 1356 manual shift transfer case

[Olden Slowe]

‘94 F350 4x4 7.3 IDI Turbo diesel with zf5 s-42 transmission, and manual shift transfer case. There is oil accumulation on the rear of the transfer case at the portion of the casting that has the 2H 4H 4L embossed “hole”. I understand that the casting is the same for the electric and manual shift versions, but what would cause a leak there on the manual shift case and how do I fix this? Thanks

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[Black dawg]

Is there a circular crack there?

If nothing is broken, I would clean it up good and fill that cavity with ultra grey.

 

[rreegg]

I have the manual shift tcase as well and don’t know much about them… with this small amount of grease/oil what happens if you leave it?

Agree with cleaning it up and monitoring but personally wouldn’t fill with rtv

 

[offroad-anarchy]

My biggest question is how did you get that pic? How did you get the shift shaft out ???

Cheers, Pete

 

[Clb]

My 93 has less than 61k on it.
It's had a dry leak stain, since 37k

 

[rreegg]

My biggest question is how did you get that pic? How did you get the shift shaft out ???

Cheers, Pete

It’s visible from under the truck and separate from the shift shaft. I’ve always been curious what it’s for, not sure if it can be manually turned as an aux control or not

 

[offroad-anarchy]

It’s visible from under the truck and separate from the shift shaft. I’ve always been curious what it’s for, not sure if it can be manually turned as an aux control or not

Ok now I see, it's the back of the transfer case. I have another problem with my 4x4 shift linkage, but it's unrelated to this so I'll put it in a different thread. Haven't been able to find a solution other than strip it down and lube it up, which isn't my issue

Cheers, Pete

 

[jwalterus]

Clean it up good and check it again, looks to me like the issue is above that and it's just accumulating there.....

EDIT: I do mean clean EVERYTHING, brake clean and wire brush.......

 

[asmith]

It’s visible from under the truck and separate from the shift shaft. I’ve always been curious what it’s for, not sure if it can be manually turned as an aux control or not

on the electric ones I know you can. There was a guy on the Bronco forums that sold a manual switch that you could install right there and engage the 4 wheel drive if your electronics failed. It was called the shiftster. Not sure on the manuel transfercases if the internals are any different or not, but I would lean to they are the same.

 

[Black dawg]

The hole isn't drilled all the way through on the manual cases.

 

[Olden Slowe]

Thanks for all the replies. I cleaned up the area, was unable to detect any obvious cause. I did not see a leak above the area or any problem with the casting. I changed the transfer case fluid. Hadn’t been done in forever but fluid volume was fine, fluid was dark but looked good. Will keep an eye on the cleaned up area and see if any more oil accumulates.

 

[SDEconVan]

Late to the party. I have rebuilt a few of those cases and that boss is most likely not drilled through. In most cases the leak won't run "uphill," unless a spinning shaft for example is slinging oil. Might be a source up above that casted boss. You can see a video I did a while back where I have the BW1356 all apart and see for any ideas where a leak could come from. Here's the link to that video, it's about half way into it at 21 minutes:

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