yo DW,
WELCOME
Mount Fabrication Info, using 78-79 transfer case bushings in an 84
Source: by my pal here, justshootme84 (Randy Z, Casual Mudder) at
http://www.supermotors.net/clubs/superford/registry/1133/52866
Mount Fabrication, using 78-79 transfer case bushings in an 83
Source: by Deviousfred (Fred)
Fred wrote; "...I cannot and will not take credit for this idea. A fellow FSB member actually posted about it and I saw it there. Figured a write up about it was in order.
Miesk5 NOTE; it was justshootme84!
It all started when I saw the trans mounts on my Bronco were shot when I was pulling the transmission. No big deal, I'll get new ones. Went down to Autozone to pick em up and the one they were giving me looked nothing like the ones I needed. Mine was made up of 4 rubber pucks and the one at Autozone was a one piece insulator.
The ones I needed on the left, the one they were giving me on the right.
http://www.supermotors.net/getfile/72318/original/transxmbr.jpg
asked about the pucks and they knew nothing about them. Came to FSB to see if anyone else had run into this problem and sure enough I found exactly what I needed. The parts are dealer items only, in may cases not stocked, out of production, and ridiculously overpriced.
http://i296.photobucket.com/albums/mm161/Deviousfred/Bronco/IMG_20110613_142124.jpg
see all the pics at Fred's PB site @
http://s296.photobucket.com/albums/mm161/Deviousfred/Bronco/?start=all
poly transfer case mounts for late 70's Bronco with an NP205. They are available from Bronco Graveyard for $15 a piece (2 are needed for this.)
http://broncograveyard.com/bronco/i-21660-transfer-case-mount-black.html
Transfer Case Mount, Black 1978-79 Ford Bronco
These re-engineered mounts have lead the industry and are in demand, both on the track and on the street. Impervious to under car fluids. A solid replacement for old rubber stock mounts. This is the round mount on the rear of the transfer case. $15.00
these is one issue here that needs to be addressed in order for this to work. The hole in the crossmember for the original mounts is about 1-1/2" in diameter and the t-case mounts to be used are designed to fill a 1-1/4" hole.
Easy fix though. I picked up some 1-1/4" ID washers to be welded onto the crossmember.
While I was at it, I picked up some new hardware. 9/16" bolts 4" long, I would recommend 3.5" long though.
So onto to the welding. Clean and prep the surfaces to be welded. I plan on welding from both side, so I cleaned both sides. For this I used an angle grinder with a wire wheel.
Washers will be welded to the underside of the crossmember as to not increase the height of the drive angle. Center them in place and tack them from the top side. For this I used my Lincoln wire feed welder. A very affordable welder for hobby welding jobs.
I flipped the crossmember over and laid down four beads.
Repeat with the other hole and washer
Painted all the bare surfaces to prevent rust and checked for fitment.
The holes on the plate that mounts the crossmember to the actual transmission have to be enlarged to about 5/8" to accommodate the 9/16" bolts.
