Ok... I have a few finished diaries (A4LD, A4LD Valve Body and the 5R55E Valve Body Rebuild Diary (one of my most popular ever). I am in the infancy of the 4R70W Diary, and now I'm starting the BW 1354 Diary? Well, I thought I'd put out a little teaser. I have an A4LD to rebuild this weekend for someone, and then I thought maybe I'd dig into the Borg Warner 1354 Transfer case - the one used by Ford in the early Explorers. Now mind you, I know absolutely nada to speak of about transfer cases, so I thought this might be a good one to rebuild together with you all and we can all learn together... through the magic of pictures, this site and the internet. I have a 1354 on site to rebuild. It's usage history is a little uncertain, but I cleaned it all up and externally it looks practically new. It came out of a 91 Ranger. I searched around for a rebuild kit and lo and behold found a great site online that sells kits, and chains for most transfer cases (including the 4405, which will be the next Diary after everything else gets done - I have one of those thanks to Section425. (And a 96 2WD 4R70W so I now have 2 of those to build, one 4WD and 1 2WD). I digress. When the rebuild kit came today, I opened the package and laughed out loud when I read the label on the parts, mounted on cardboard under shrink wrap. Know how we sometimes laughingly call our Explorers ..."Exploders"... yep... here is the printing: Mind you this is from NatPro which is a major national mfgr of auto parts! Anyway, The rebuild kit costs $100, and a new chain is another $100. I know enough to know that chains DO wear out, but for $100, before comitting to buy a new one I thought I'd wait til I had the transfer case busted open to see the condition of the one in there and read up on when it should be replaced. But I did buy the rebuild kit. It consisted of that cardboard sheet, with 3 ball bearings, a bronze bushing, a needle roller bearing bushing, two small plastic thingies (technical name), two nuts (look like locknuts), and something in the middle wrapped in corrosion resistant paper. As I looked at the corrosion paper I noticed it was on inside out, the wrapping said "This side towards part to be protected" or something like that and it was on the outside. I didn't take a picture but what was inside was a plastic housed filter and a hose (hardly needing corrosion protection). The anti-corrosion paper was for the OTHER parts, and that was why it was on inside out. Here is a pic of this these parts: Then there was a second package, with a cardboard stiffener.... It contained a cheap cardboard gasket, 3 of what, for lack of a better term, could be described as shaft oil seals (much like you see on the output shafts of transmissions or behind wheel bearings) a couple of what look like sealing rings for maybe a shaft passage into the TC and a small O-ring. Here it all is: So, that's what you get for $100. Here is our "victim". A little hard to see against the painted floor the same color.... The dark ring to your left facing you is the gasket to the transmission and the output shaft goes into that splined shaft.... the right hand yoke is for the front wheel drive.... directly on the opposite side of the input is the main rear wheel output - power to the rear wheels is trabnsmitted straight through. Another view of the area that connects to the transmission and the splined input. Now on the other side... you can see the shift motor, the rear wheel output, and an arrow points to the infamous "brown wire" Here's a close up of the shift motor and to finish, a closup of the "brown wire" and where it goes in the connector For now, stay tuned. We can all have fun on this one together. Maybe by the time we tear into the 4405 we collectively will know a little more than we do starting on this one.