Jump to content
66-96 Ford Broncos - Early & Full Size
Sign in to follow this  

Transfer case swap

Recommended Posts

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

Share this post

Link to post
Share on other sites

Yo TG,

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



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 Flange 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/Flange 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:

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.
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. 




Share this post

Link to post
Share on other sites


Overwrote this:

BW 1356 Manual (F1TA-7A195-EA) Exploded (shown with optional PTO plate)

1 7045 Shaft Nut (163-203Nm, 120-150 lb-ft)
2 7B368 Output Shaft Yoke Washer 
3 7052 Oil Seal 
4 7B215 Yoke to Flange Seal 
5 -- Extension (Rear Spline) Cap, Bearing (Rear Yoke/Flange) (Serviced As Part of 7085 Assembly) 
6 7085 Extension Assembly (Rear Spline) Cap Assembly, Bearing (Rear Yoke/Flange)
7 7A443 Bolt and Washer Assembly (30-49Nm, 22-36 lb-ft)
8 -- Flange (Rear Flange) (Serviced As Part of 7B214 Assembly)
9 7917 Ring, Snap
10 7025 Bearing 
11 7917 Ring, Snap
12 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 Hub
17 7D126 Spring, Lockup
18 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, Pump
24 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 Fork
49 -- Retainer (Serviced As Part of 7289 Assembly) 
50 7289 Fork Assembly, Shift, 2W-4W 
51 7240 Shift Rail
52 7219 Shift Fork Spring
53 7C349 Spring, Detent
54 7C191 Bushing, Detent 
55 7F063 Cam, Shift
56 7288 Shifter Shaft Seal
57 7B106 Lever, Shaft and Pin Assembly
58 7005 Case Front 
59 -- Pin Dowel (Part of 7005) 
60 7L027 Oil Pan Magnet
61 7917 Ring, Retaining 
62 7061 Output Shaft 
63 7177 Sprocket, Driven 
64 7119 Thrust Washer 
65 7917 Ring, Retaining 
66 7A029 Chain, Drive 
67 -- Yoke (Serviced As Part of 7B214 Assembly)
68 7005 Case Rear

F2TZ-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.

Share this post

Link to post
Share on other sites

Hi miesk5,

I know its a flange 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

Share this post

Link to post
Share on other sites


All I know is to go by the diagram.

Here is the 1996 Bronco Workshop Manual




Section 07-07A: Transfer Case, Electronic Shift
Or manual shift
My COMCAST keeps freezing. Remove 
Yoke to Flange Seal

Share this post

Link to post
Share on other sites

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


Edited by tjg8675

Share this post

Link to post
Share on other sites


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 Screw 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.

Share this post

Link to post
Share on other sites
You are commenting as a guest. If you have an account, please sign in.
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

Sign in to follow this