Tansfer case part / Sunday project going downhill fast

[carlsbadbronco]

I have a New Process 208F transfer case on my 82 bronco. There is a part on the bottom of the case that has a bolt. I took the bolt out when removed from the vehicle. When I put the transfer case back in the truck, I'm not sure exactly how those two or three pieces are supposed to go back in. I know that they are supposed to make it hard to shift from 2 to 4 wheel instead of real easy like it is without these parts installed. The first piece to go in the transfer case is what looks like a ball bearing with a stem on it. A spring also came out of here. The spring lines up over the ball. Now what I don't know is.... if a little 1/2": long rod that I think goes in with these parts, actually goes in here. Trying to put the little rod in also makes this whole assembly so tight that I don't know now for sure if it was supposed to even be with this in the first place. Can I just snug the bolt up tight with the spring and the bearing to make the shifter where it feels like it's supposed to. I can actually tighten it as far as to where I can't shift the transfer case. Does anyone have any suggestions?

 

[Seabronc]

It ain't supposed to be hard to shift from 2WD to 4HI and back. It is supposed to be hard to shift into 4Low. Infact you should have to have the truck in neutral in order to shift into 4Low.

If that is the poppet plunger you are talking about, it is illustrated in the attached photos. The Poppet ***** should be tightened to 20-25 ft lb.

Good luck,

>-

 

[carlsbadbronco]

Thanks Seabronc. That's the part. I appreciate it!