T-case tech

[Justin]

Hoping to swap my t-case for one I'm picking up this weekend. Any advice from you all out there in Bronco-land? Haven't done one before, just want to make sure I don't screw anything up. Sounds like there are some bearings I need to be careful of from some Google research, but wasn't able to find much detail. Anyone interested in making a tech day out of it? Anyone who wants to make the trek is welcome and I'm happy to schedule the swap for when folks could come.

[BNC04]

Hi,, Have you done this yet? I'm looking at a Bronco that will need to have the T case looked at and most likely dropped and I'm in the same boat you are in as far as experience in doing it. If you need a hand on yours let me know. I will see if I can get by to assist and learn as well. I'm in Longmont by the way.

Brett

[Viperwolf1]

Justin,
Remember those roller bearings in the outut shaft? Those are the ones you need to be careful about when you remove the tcase from the adapter. The input shaft and gear stay in the adapter. You could remove the rear output assembly first to prevent dropping the rollers and install it last.

If you separate the adapter from the trans you could run into the same type of thing with the trans bearings, depending on the trans you have. The stock 3 spd has a problem dropping roller bearings unless you lock it into 1st gear. When the adapter is pulled it tends to pull on the output shaft of the trans. I'm not aware of any issues with the NP435. C4 has no issues.

[Lobobronco]

Great question!

No problems with the NP435 (have dropped it several times without any problem). As for dropping it, it put a quick jig together and it seems to work well with a floor jack (used several times now). Will hopefully drop the T-case in Tina tomorrow. Looks like I was about to have a mess with the 3sp (not in first currently). Any other things to be aware of? Was planning on pulling the t-case and then motor and tranny as one. Sorry for the hijack :)!

Viper...thanks for the heads up. What is the key to 1st..why does that save the day?

Matt

[crawlercreations]

Great question!

No problems with the NP435 (have dropped it several times without any problem). As for dropping it, it put a quick jig together and it seems to work well with a floor jack (used several times now). Will hopefully drop the T-case in Tina tomorrow. Looks like I was about to have a mess with the 3sp (not in first currently). Any other things to be aware of? Was planning on pulling the t-case and then motor and tranny as one. Sorry for the hijack :)!

Viper...thanks for the heads up. What is the key to 1st..why does that save the day?

Matt

1st gear will hold the output shaft into the transmission preventing it from getting pulled out with the t-case causing the bearings to drop. Nothing else to be aware of besides the output shaft bearings. If you go gently those shouldn't be an issue either. I have pulled my t-case 4 times without dropping them.

[Lobobronco]

Thanks Crawler...Hopefully it get's dropped in the next few days.... 3 spd is new to me!

Hijack over :)!

Matt

[Justin]

Brett, I don't even have the case all the way out yet, so I'll absolutely take you up on your offer. I'll need some help with the heavy lifting and can always use an extra set of hands. Are you available this weekend? Viper, thanks for the advice! I've been studying up, so I think I'll be OK. I'm trying to source some new bearings, as I don't trust anything that comes out of my original t-case, but it'd be nice to not have to pull the observation cover. I've got an NP435, so there shouldn't be any issues if I end up pulling the adapter. Getting the t-case out without doing that is turning out to be a major pain, so I may pull it to make the install easier. Lobo, hijack away. If you look around the original Ford instructions on how to pull the t-case have specs for a little tool you can make to keep first gear engaged.

[BNC04]

Justin, Let me check with my social adviser as far as weekend plans. I know I am working Saturday night from about 6pm to sometime early Sunday morning.
I should be able to get a handle on scheduling by this afternoon.


Going to look at a Bronco in Firestone that's for sale early this afternoon that seems like it has a Xfer case problem So helping you will get me some experience if I buy it and need to work on that one.

Unfortunately since I have no experience in this, my assistance will be the brawn variety in this case. ( Pardon the pun )


Here are a couple of writeups I found when doing some research. You probably have already seen them.
http://www.mallcrawlin.com/forum/showth ... %20twin%22

Slick way of retaining bearings.
http://www.wt4x4.net/tech/twinstick.htm

Brett

[Justin]

Brett, I'll take whatever you can do. I've got a pretty good idea of how to do this (says the guy who's never done this before-famous last words), just would find the extra muscle invaluable. I need to check with my social adviser re: whether we have anything going on this weekend, but I think I'm wide open.

[BNC04]

Justin,, Social Coordinator just d her head into my office.

Saturday I'm open to about noon ( still in a little flux about what time I have to go to work that night and I'll need a nap most likely. lol )

I'm usually up and about by 6 in the mornings (Weekends)

Sunday I'm open to about 2 then I have to go to a birthday part for the niece and nephew.


Brett

[Gregg]

Keep me in the loop. You'll need someone around to ask stupid questions. I'm available Sat and Sun.

Justin- if you can get a time/date set, post it up with an invitation. See if we (you) can get a big turn out.

Shawn "Gregg"

[BNC04]

Northern boys tearing crap apart !!!!!!


LOL..


Let me know if you need me to bring anything also, I have some jack stands and what not.

Brett

[Gregg]

Saturdays out for me but Sunday is a go.

[BNC04]

I can do Sunday morning.

Brett

[Lobobronco]

Unfortunately I will be out as well! Out of town this weekend!

Actually got mine out most of the way last night (darn previous owner engine swap and my being too cautious)!

What I dealt with...

Easy for the most part (easier with the NP 435 in the other bronco).

I have the hurst 3 speed. Connects to the T-case. Unbolt everything and depending on the hole, you may or may not be able to squeeze out. No problem...leave it there hanging and once you lower the T-case a bit it will pop out of the hole, so just make sure everything is out of the way. With that being said...make sure you get it back in place when putting it back up there for easy bolting.

As for sticking and staying in first...the book tells you to make a tool. You could easily use a couple of bolts and strap or whatever. I made sure it was there and will put the saver in there after the T-case is out and before I pull the motor. Thanks Viper and Crawler for the great reminder/tip (I almost made the fatal mistake).

I typically put a jackstand under the tranny for support. Apparently either the tranny and new motor sit too high or I have it resting too high. Time ran out and I was by myself, it was late, and no other jack to make it right and make me feel safe (darn...a lot of excuses). Note too self...buy another floor jack and quite being the safety nazi.

Pulled the bottom bolt from the adapter and gear oil flows...do this the night before.

Other than that...straight forward.

As to my problem...hit the back cross member (if you call it that), so make sure of your clearances.

My 2 cents and weeks experience (as stated before....still not worth that...:) )!

Matt

[Justin]

Nothing wrong with being a safety nazi, especially when you're working by yourself. Better to take a little longer than come up short a finger (or worse).

[BNC04]

Yesterday I got to meet Justin, Cool guy and a nice bronco!
Somewhere in between BS'ng and looking for tools and parts we finished up the removal and then re-installed the T case yesterday. Had a great time and it was nice to meet a fellow Bronco enthusiast and just talk Bronco's.

All went well considering neither of had done this before. The needle bearings were pretty easy to keep in place with the grease applied. Using the transmission jack was a definite plus and 4 hands I think were helpful to align and get the bolts started.

Couple pics I took






Brett

[Gregg]

Hey guys. Sorry couldn't make the trek. I was all set to go but the rig wouldn't start. Spent the rest of the day going back and fouth to Adv Auto and tracking down the fuel problem. I should have a new fuel pump to put in after work today. Either way I was pretty bummed not to meet up. Let's meet up soon.
-Shawn "Gregg"

[Justin]

I was bummed that your truck wouldn't start, would have been fun to have another person over! Hope you get it worked out, my offer of help stands should you need it. It'd be fun to put together a get together for us northern people, maybe in Longmont or somewhere around Johnson's corner.

Brett, thanks again for the help! The second set of hands made a massive difference, as did the transmission jack (thanks Zack!). So far things seem to be running well other than an odd gear sound for the first mile or two. I'm guessing it just took a little bit for the gear oil to work all the way into the bearings. I'll know more as I get more than 3-4 miles on it. Overall the swap was easy once I figured out how to get to all the bolts (and got the Herculiner off the interior bolts for the access panel the PO put in.)

[BNC04]

That stinks that you couldn't make it,, A little get together sounds good to me!
Justin, save that green handled adjustable for me. lol

In other news...I was poking around the bronco today and removed the tunnel cover for the sifter because it was way loose.. I found a few things. all the bolts that attach the shifter bracket to the transmission were extremly loose !!. I have one more bolt to tighten on the bracket to snug things up there but it is 400% better! I need to trim the tunnel just a bit more around the shifter to prevent the rails from hitting the tunnel cover in Reverse and 1st.
I also found out that I have a J shifter D20 vs the T shift like I should have.. Had to lube the rails to get it to work smoother and is working much better now.

I was laughing, the first piece of work I attempted on this bronco required a grinder to get a stripped screw out of the 3 sp tunnel adapter! !! LOL.. It's going to be a labor of love !

Brett