Troubleshooting the

Borg-Warner 1354 &

1356 Transfer Case
Control Module
For many years,
Ford vehicles with
electronic shifted
4WD used a small
external electric
motor to rotate
a cam inside the
transfer case.

he 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 controlled by a GEM module, see the May
2001 GEARS magazine article Another
GEM of a Problem, written by Lance
Wiggins. Since there are many versions of this system, please refer any
mechanical transfer case or hub concerns 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 specific system
The vehicle must have four
matched tires and correct tire
pressure

14

dave-skora.indd 14

by Dave Skora

Figure 1: Eight Pin Square Connector

Both drive shafts must be

straight with good U-joints
Both hubs must lock and
unlock correctly (if applicable)
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 vehicle 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.
Its 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
GEARS January / February 2006

12/28/05 2:02:54 PM

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12/21/05 11:49:42 AM

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

Pin
1

5 PIN FLAT CONNECTOR

Wire Color
Wht/lt blu

Function
Shift control switch feed

4x4 input from dash (4HI switch)

Dk blu

4x4 input from dash (4LO switch)

Org/lt blu

4LO indicator light

Brn/wht

4HI indicator light

Gray

Pin

8 PIN FLAT CONNECTOR

Wire Color
Red/lt blu
Red/wht
Lt grn
Lt blu

2
3

Function
(M/T) Neutral safety switch
(A/T) Neutral safety switch
Speed sensor (+)
Speed sensor (-)

Switch plate

Pink/Y

Switch plate

Wht

Switch plate

Brn/wht

Switch plate

Org/wht

Switch plate ground

Pin
1
2
3
4
5
6
7
8

Y/wht

Function
N/A
Ground
Ground
Electric motor
Magnetic clutch
Electric motor
Ignition
Battery voltage

8 PIN SQUARE CONNECTOR

Wire Color

Blk
Blk or Blk/org
Org
Brn
Y
R/Y or Wht/Ppl
Bk/W or DG/LG

Spec
5 Volts
5 volts in 4HI
0 volts all others
5 volts in 4LO
0 volts all others
B+ 4LO light off
0 volts 4LO light on
B+ 4HI light off
0 volts 4HI light on
Spec
12 volts in N
12 volts in N
225-275 ohms between pins 2 & 3

0 volts in 2HI & 4LO

12 volts in 4HI
12 volts in 2HI & 4HI
0 volts in 4LO
0 volts in 2HI & 4HI
12 volts in 4LO
0 volts in 4HI
12 volts in 2HI & 4LO
Always less than 0.10 volt

Spec
Less than 0.10 volt
Less than 0.10 volt
See testing SYMTOM-1
1.5-5.0 ohms
See testing SYMTOM-1
Key on 12 volts
12 volts

Figure 2: Pin Voltage Chart

Its 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.
case control module resets itself. If not,
continue with the following tests. Use
the PIN VOLTAGE CHART to check
16

dave-skora.indd 16

Figure 3: Eight Pin Flat Connector

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
GEARS January / February 2006

12/28/05 2:03:20 PM

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

If the electric motor

wont 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.
the speed sensor resistance at connector 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 connector. Measure the magnetic clutch
resistance between the harness side

18

dave-skora.indd 18

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 electric 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 selector 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 vehicle to engage each electric motor position. Repeat this test for the remaining
pins 5, 6 and 7. If the electric motor
wont 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.

GEARS January / February 2006

1/5/06 3:47:33 PM

SYMPTOM 2 Wont shift to

4LO
Make sure the speed sensor circuit
is good. Make sure the module is getting 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

GEARS January / February 2006

dave-skora.indd 19

Figure 4: Five Pin Flat Connector

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 diagnose. When symptoms like these occur,
following the six-symptom diagnostic
procedures will help speed things up.

19

1/5/06 3:48:59 PM