Borg warner 1354
Hi, I am new to this site and am in need of your help and expertise. Sorry if this is long winded, I just wanted to give you all the history.
I have a 1984 Mazda B4000 extended cab v6 4x4 with the bw 1354 electric shift transfer case.
I had issues with the original transfer case some time in 2006 in that it would no longer shift with the dash buttons. I tested the two fuses and they were good so I replaced the shift motor and cut the infamous brown wire.
It shifted fine for a while with the new motor then quit again. This time I replaced the motor again and soldered the brown wire together and insulated the connection, but this time it would not shift by the dash buttons. So I assumed the control module was at fault and got one at the local bone yard. Nope that did not work either. Then I assumed the replacement control module was bad and got a second replacement module, no luck on that one either.
My neighbor got me a wiring diagram and I was able to find which wires to jump from the control module wiring connector. The shift motor would operate and change the transfer case into high and low ranges. I checked all the switches and wiring to the control module all had the correct voltage, switches were working, and both the fuses still tested good. Since I was able to get it into 4 wheel drive I said that was good enough for now.
I have been driving it for 3 years like this when the transfer case jumped into neutral after hitting a large bump. I was only able to get it back into low range and tried to limp home only to have it lock up all wheels in the street and not budge. After towing it home I removed the transfer case and split the case to find a burnt mess, lots of loose ball bearings, twisted metal, and shavings. Looking at that mess I decided to try the local bone yard again and found a replacement electric shift transfer case for $200 with an intact brown wire.
After installing the new transfer case and resetting the control module to locate the transfer case position; everything was working fine. It shifted from the buttons and I was happy again. I tested my other control modules and they worked too. Now after sitting for three months with everything working when I last left it I am back to no shifting with the buttons and back to shifting by jumping wires at the control module plug.
I saw on your site a website for more info on what the wires do, however the link is no longer valid. (
http://www.gearsmagazine.com/2006-01/2006-01_14.pdf) Does any one have that PDF file I could get a copy of? Where can one obtain those ford CD’s? Any ideas as to what is going on? My thoughts go to the brown wire possibly loose in the connector, or the electric clutch in the transfer case, or the control module not getting a signal from the transfer case.
Thanks for your help
Mark