Replace the transfer case motor/actuator (shift motor) that controls electronic engagement of 4WD modes on the BorgWarner transfer case.

Warnings

Tools required

Parts

• Transfer case shift motor/actuator × 1 — Use OEM Ford BC3Z-7G360-A or equivalent
• Transfer case shift motor gasket/O-ring × 1 — Often included with motor

Fluids

• Motorcraft Transfer Case Fluid — 2.5 qt

Preparation

1. Park vehicle on level surface and set parking brake firmly
2. Place wheel chocks behind rear wheels
3. Allow transfer case to cool completely if vehicle has been driven
4. Shift transfer case to 2H (two-wheel drive high) position using dash control
5. Turn ignition off and remove key
6. Raise front of vehicle and secure on jack stands at frame rails
7. Remove driver side front wheel to improve access if needed

Procedure

1. 1

   Locate transfer case actuator motor
   Position yourself under the driver side of the vehicle. The transfer case is located behind the transmission. The actuator motor is mounted on the rear driver side of the transfer case housing with an electrical connector and three mounting bolts visible.
2. 2

   Disconnect electrical connector
   Locate the electrical connector on the actuator motor. Press the locking tab and pull the connector straight off the motor. If connector is corroded or stuck, use a small amount of penetrating oil and gently work it free with a pick tool.
3. 3

   Position drain pan
   Place a drain pan with at least 3 quart capacity directly beneath the actuator motor location. Some transfer case fluid will drain when the motor is removed, though most fluid remains in the case.
4. 4

   Remove actuator mounting bolts
   Using a 10mm socket, remove the three bolts securing the actuator motor to the transfer case housing. Keep bolts organized as they will be reused. Support the motor with one hand as you remove the final bolt to prevent it from falling.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
5. 5

   Remove actuator motor
   Carefully pull the actuator motor straight out from the transfer case housing. The motor shaft engages with the shift fork inside the case, so pull firmly but steadily. Allow any fluid to drain into the pan. Inspect the motor shaft for wear or damage.
6. 6

   Inspect and clean mounting surface
   Inspect the transfer case mounting boss for cracks or damage. Use a wire brush or shop towel to clean the mounting surface, removing all old gasket material and debris. Check inside the bore for metal shavings or contamination that could indicate internal damage.
7. 7

   Check transfer case fluid level
   Locate the transfer case fill plug on the rear passenger side of the case. Remove the fill plug with a 3/8 inch ratchet (square socket). Fluid should be level with the bottom of the fill hole. If low, note this for refill after motor installation.
8. 8

   Prepare new actuator motor
   Remove new actuator motor from packaging. Verify it matches the old unit exactly, particularly the shaft length and electrical connector type. Install the new O-ring or gasket onto the motor body, ensuring it seats properly in the groove. Lightly lubricate the O-ring with clean transfer case fluid.
9. 9

   Install new actuator motor
   Align the actuator motor shaft with the shift fork engagement point inside the transfer case. The motor will only install in one orientation. Push the motor firmly into the housing until it seats flush against the mounting surface. The shaft must fully engage with the shift mechanism inside.
10. 10

    Install and torque mounting bolts
    Install the three mounting bolts by hand, threading them in evenly. Torque all three bolts to specification in a cross pattern to ensure even seating of the motor and proper O-ring compression.
    ⚠Over-torquing can crack the actuator housing or transfer case. Use calibrated torque wrench.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
11. 11

    Refill transfer case fluid
    Using a fluid pump or transfer case fill bottle, add Motorcraft Transfer Case Fluid through the fill hole until fluid begins to drip from the fill opening. This indicates proper level. Account for any fluid lost during actuator removal (typically 0.25-0.5 quarts). Install and hand-tighten the fill plug.
12. 12

    Reconnect electrical connector
    Push the electrical connector firmly onto the new actuator motor until the locking tab clicks into place. Tug gently on the connector to verify it is fully seated and locked.
13. 13

    Reinstall wheel if removed
    If the driver side front wheel was removed for access, reinstall it and hand-tighten lug nuts in a star pattern. Lower vehicle until wheel just contacts ground, then torque lug nuts to specification in star pattern.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)
14. 14

    Lower vehicle and perform system test
    Lower vehicle completely and remove jack stands. Start engine and allow to idle. Use the transfer case selector switch to cycle through all positions: 2H to 4H to 4L and back to 2H. Listen for proper motor operation (smooth whirring sound) and verify dash indicator lights change appropriately for each mode. Each shift should complete within 5-10 seconds.

Reassembly

1. Ensure all mounting bolts are torqued to specification
2. Verify electrical connector is fully locked onto actuator
3. Confirm transfer case is filled to proper level with correct fluid
4. Double-check that no tools or parts were left under vehicle

Verification

• Start engine and cycle transfer case through all shift modes (2H, 4A if equipped, 4H, 4L) multiple times
• Verify dash indicator lights correspond correctly to selected mode
• Listen for smooth actuator motor operation without grinding or clicking noises
• Test drive vehicle in 2WD and 4WD modes to confirm proper engagement
• Check for transfer case fluid leaks around actuator motor after test drive
• Verify no warning lights or error messages appear on instrument cluster

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