Transfer case swap

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tjg8675

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Hi all,

I am swapping my transfer case out with a remanufactured t-case and am wondering if I need a gasket betwern the t-case and the adapter to the rear driveshaft?

It would be a gasket with 4 holes, if the gasket is required what is the part #?

Thanks for the help

 

miesk5

96 Bronco 5.0
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Yo TG,

As you know, 1356; 87-89 output is yoke; 90-96 is ******.  The manual shift diagram confuses many because it has a finger pointing to Yoke right under Bronco.

Try NAPA

Some tips by a friend who has swapped a 1356 electric to manual; 

Seal Kit (Don’t buy the Jeff’s Bronco Graveyard one. It’s actually meant for a Truck as it has only 3 large input/output seals, and one is for the slip yoke style rear output, so you end up having to get one more seal that will work with the Bronco ****** rear output. All three large seals for the input and front and rear outputs are the exact same on the Bronco.Oil pump kit (this kit also included new shift fork pads).You’ll need to look at your chain for slop, look at the forks for wear, look at the sprockets for wear, look at the planetary for wear/slop, from the 5th link above, check and see what kind of play you have in the shift lever that goes into the case (push/pull it). Too much play here will allow the shift fork to come out of the track within the case, causing a lot of problems with engagement/disengagement. A bearing kit is also a wise idea with higher mileage/fluid-abused Tcases.Beyond this, there is one area that ALL cases broken into should have addressed, and that is wear at the case walls enclosing the oil pump locating arm. But first let’s break the case halves apart and do a quick tear down:• Drain fluid, if not done already.• Remove Front & Rear Yoke/****** bolts. Torque on these is about 150ft lbs. so you’ll need to hold the case and use a big extension for leverage. The socket is a 1 ¼” 12pnt. I’ve heard that thick wall sockets don’t fit. Also note the washer and seal for reinstallation (new seals are included in the seal kit).• Remove the 4 Torx bolts holding the rear tail shaft on. Remove the large C clip on the shaft. Note: All my torx case bolts (these 4 + the case bolts described next), once removed, had lots of magnesium shavings in the bolt holes. Messy when trying to keep things clean. Clean out the bolt holes before getting real clean with the case internals, and really, clean the case externally to save yourself some headache later.• Remove all the torx case bolts, and carefully separate the case halves. Note: there is a locating pin at each end, and notate the location of the spring for the shift fork within:
109_0948.JPG


There are (6) ½” bolts that hold the Tcase to the tranny housing adapter. It will leak just a little once unbolted. There is very little room between the Tcase bolts on the passenger side and the stock exhaust. The bolts are not that tight since it’s all magnesium (torque on these is about 40 lb/ft., they had traces of red locktight on removal, so I used a little on reinstall. NOT the permanent, just red locktight high strength). • You need a gasket (included in the seal kit, don’t damage it). It takes no sealant. Surfaces must be clean.• Chock the wheels and place the tranny in Neutral, making install of the slip shaft easier while “clocking” the rebuilt manual Tcase into proper position.109_0987.jpg
Make sure when you are putting the rear Tcase nose piece back on you don't cover that rectagular hole with sealer. That's a passage for fluid. 

bw1356manshift.jpg

&

bw1356esof.jpg

 

miesk5

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Yo,

Overwrote this:

BW 1356 Manual (F1TA-7A195-EA) Exploded (shown with optional PTO plate)IF THE IMAGE IS TOO SMALL, click it.1 7045 Shaft Nut (163-203Nm, 120-150 lb-ft)2 7B368 Output Shaft Yoke Washer 3 7052 Oil Seal 4 7B215 Yoke to ****** Seal 5 -- Extension (Rear Spline) Cap, Bearing (Rear Yoke/******) (Serviced As Part of 7085 Assembly) 6 7085 Extension Assembly (Rear Spline) Cap Assembly, Bearing (Rear Yoke/******)7 7A443 Bolt and Washer Assembly (30-49Nm, 22-36 lb-ft)8 -- ****** (Rear ******) (Serviced As Part of 7B214 Assembly)9 7917 Ring, Snap10 7025 Bearing 11 7917 Ring, Snap12 7100 Shift Collar Hub 13 7127 Caged Needle Bearing 14 7A010 Plug, Pipe (9-23Nm, 7-17 lb-ft)15 7917 Ring, Retaining 16 7D164 Lockup Hub17 7D126 Spring, Lockup18 7106 Lockup Collar 19 7177 Sprocket, Drive 20 7A210 Hose 21 382486-S Clamp, Hose 22 7A291 Pump Housing to Case Bolt (4-4.5Nm, 36-40 lb-in)23 7E215 Retainer, Pump24 7A152 Cover, Pump 25 7A149 Housing, Pump 26 7A250 Pin, Pump 27 7A205 Spring, Pump Pin 28 7061 Output Shaft 29 7100 Shift Collar Hub 30 7A398 Front Planet 31 7C122 Ring, Retaining 32 7A153 Ring Gear 33 7A098 Filter, Oil 34 -- Gear, PTO (with PTO Only)35 7917 Ring, Retaining 36 -- Ring, Retaining (Part of 7B215) 37 7166 Case Deflector Gasket (with PTO Only)38 7165 Transfer Case Cover (with PTO Only) 39 381673-S Bolt (with PTO Only) 40 7034 Vent 41 7E440 4WD Indicator Switch 42 -- Setscrew (Part of 7E440) 43 -- Fork, Reduction (Serviced As Part of 7289 Assembly)44 -- Facing, Shift Fork (Serviced As Part of 7289 Assembly)45 7289 Ford Assembly Reduction 46 7235 Roller, Cam (Service As Part of 7289 Assembly) 47 -- Pin (Part of 7289)48 7C430 Facing, Shift Fork49 -- Retainer (Serviced As Part of 7289 Assembly) 50 7289 Fork Assembly, Shift, 2W-4W 51 7240 Shift Rail52 7219 Shift Fork Spring53 7C349 Spring, Detent54 7C191 Bushing, Detent 55 7F063 Cam, Shift56 7288 Shifter Shaft Seal57 7B106 Lever, Shaft and Pin Assembly58 7005 Case Front 59 -- Pin Dowel (Part of 7005) 60 7L027 Oil Pan Magnet61 7917 Ring, Retaining 62 7061 Output Shaft 63 7177 Sprocket, Driven 64 7119 ****** Washer 65 7917 Ring, Retaining 66 7A029 Chain, Drive 67 -- Yoke (Serviced As Part of 7B214 Assembly)68 7005 Case RearF2TZ-7210-K 4X4 Shifter Assembly (Mazda R2, ZFLD)F2TZ-7210-N 4X4 Shifter Assembly (E4OD)F2TZ-7210-P 4X4 Shifter Assembly (T18, C6, AOD, ZFHD)F2TZ-7B051-A Control Rod (Mazda R2, ZFLD 7.25" OC)F2TZ-7B051-B Control Rod (ZFHD)F2TZ-7B051-C Control Rod (T18, C6)F2TZ-7B051-D Control Rod (AOD)F2TZ-7B051-E Control Rod (E4OD)The ZF/C6 shifter detent plate also fits the Mazda M5OD-R2.

 
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tjg8675

tjg8675

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Hi miesk5,

I know its a ****** connection on the broncos (#6 in bottom bw1356 esof diagram).

What I am wondering is if #14(cap, bearing/extension - short stubby one for the bronco, part of #9 assembly) requires a gasket or some sort of sealant (to keep water out) on the side that connects it to the t-case?

2018-10-17 15.01.32.jpg

 

miesk5

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tjg8675

tjg8675

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Hi miesk5,

That manual had the answer thanks,

It says "RTV sealant on the mating surfaces of the transfer case and the bearing retainer"

Great resource, I don't know how I got on before without it . Thanks Diesel Dave

Thanks miesk5

 
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miesk5

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Yo,

Good! YW!

BTW, Note, 96 Workshop Manual is same as most earlier years especially 92-96, except for:92 through 95 uses the Electronic Engine Control, version Four (EEC-IV, aka On Board Diagnostics (OBD-I)) engine management computer.96 uses the OBD-II (EEC-V) engine management computer;4WABS (93-96);RABS (87-92);Air Bag (94-96);3 ***** Automatic Locking Hubs (Built from May 95 through 96); Spark Plug Wire Routing & Firing Order (The firing order for 1987-1993 5.0Ls is 1-5-4-2-6-3-7-8. The firing order for 1994- 96 5.0Ls & all 5.8Ls is 1-3-7-2-6-5-4-8.);R134a in 94-96;2-piece Spindle Rolling Diaphragm Seal (RDS) used on 5/95 to 96 Broncos & F Series 1/2-ton 4WD;Speed density EFI uses a Manifold Absolute Pressure Sensor (MAP), a Throttle Position Sensor (TPS), an Air Intake Temperature Sender (ACT) that gives the engine certain volumetric efficiencies over it's RPM range. Speed density EFI also uses what is called bank fire injection. 4 injectors are fired at one time on each side of the engine (only 2 wires for firing injectors from EEC-IV).Mass Air Electronic Fuel Injection (EFI), aka Sequential Electronic Fuel Injection (SEFI) in 95 5.8 California models and in all 96s. Mass Air directly reads the mass of air (or number of molecules of air). By doing this, it can detect the changes in the volume of air, in addition to it's pressure & temperature. Mass air has one separate wire for each injector & fires them twice for every power stroke of the engine. This makes the injector timing more accurate & will help emissions along with power.96 5.8 do not have the Air Injection (AIR), Secondary Air Injection; Pump (Smog Pump), Thermactor Air Bypass (TAB) & Thermactor Air Diverter (TAD) Solenoids; Diverter, Check & Bypass Valves, Cross-Over Tube, etc. But 96 5.0 does have the system.Only 95 5.8L California models & all 96 have the Differential Pressure Feedback (DPFE) Sensor instead of EGR Valve Position (EVP) Sensor.The 96, Vapor Management Valve (VMV) replaces the canister purge valve (CanP valve) used in EEC IV. But the 96 manual still shows CanP valve probably because it was a late addition to the 96 production line.The Speed Control Deactivation Switch (SCDS) in a 93 Bronco is located on the driver side frame rail, but in 94 through 96 it is on the master cylinder.Still researching other differences.

 

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