Thursday, February 27, 2014

Transfer Case Replacement - Take 1

A buddy drove about 3 hours roundtrip to pickup a transfer case I found online at car-parts.com.  It was from an '89 but allegedly it fits an '88.  True but not true we found out.

Both are a BW1356 (you can find the 13-56 stamped on the case or on the metal tag if its still attached).  However, in '89 they changed the rear driveshaft flange (the part that connects the transfer case to the drive shaft).


As shown in the picture my '88 transfer case had a double cardan style (right) and the '89 had the newer flange.  They are not the same size shaft!  The newer style is slightly bigger so it will fit on either shaft but the double cardan style will not.  Don't try to force it on with a hammer/etc.

Another issue to be aware of is that the '89 transfer case came off a lifted Bronco so the arm for the manual shift was slightly longer so I had to take retain the old hardware in order to connect up the shifter based on my current ride height.

There are a few "fixes" for this.  The first would be to find a driveshaft from a later model Bronco and use that instead.  If you found one from another model (F-Series for example) you'd have to take it to have the driveshaft shortened.  The second solution and my approach is taking the vehicle to a shop that does driveshaft work and having them create a suitable adapter.

Other tips and useful information:

- Get some tape to tape the caps of the ball joints. Electrical tape works well.  If the caps fall off the needle bearings may fall out and if you lose one the bearing is no good.

- Be sure to disconnect all the electrical connections and speedo gear before removing the transfer case so you don't break them.

- There is a seal between the transmission and transfer case.  If this seal is old be prepared for more than the 2 quarts of fluid from the transfer case to drain out.

- Buy some gasket maker like RTV or find the gasket to go between the transmission and transfer case.

- There is a guide on the C6 transmission (possibly on others too) to guide the transfer case back into the right position.

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