Took the Bronco for a drive today! The good news: it was fun. The bad news: a very bad driveline vibration. My rear driveline is likely shot, wasn't too much of a surprise. What I discovered when I pulled it, however, is that I have a decent amount of play in the rear output shaft. Maybe 1/32 or 1/16th of an inch. How much play is normal? How hard is the T-case to rebuild of this isn't? Can one person take the case out? For those of you who have done it, any tips?

They can be pulled by one person and a jack. Don't try to muscle that thing by yourself with out at least a floor jack. Preferably, you should have someone help you, just so you don't drop it on yer head, but I've pulled one by myself. As far as rebuilding the D20, from what I understand, they are fairly simple to do. I haven't done one, but I know of a couple of guys who did it and the advice I got from them was to just pay attention as to how things come apart. I've rebuilt an old T-98 Willys 3-speed transmission before and if I can do that, I wouldn't have a problem taking on the x-fer. Like I said, just pay attention to how it comes apart & it shouldn't be that hard.

Zilla, I'd love it if you could take a look. Still learning...give me a call whenever and we can set something up. T-case is still in the truck, likely will be for a little bit as I'm short on time for the moment.

Hey Justin....

As other mentioned it can be pulled by one person, but it is not too much fun. I built a quick jig to work with the floor jack and life got much better. Super simple, but it will be around for a while.

Just built it when the T-case was in the truck so it would sit at the right angle to get back in. Had my wife steer the jack and it was back in and lined up in minutes.

Many apologies for the picture quality!

Matt

Hmmm, not a bad idea. I may just spring for a Harbor freight transmission jack if I decide to pull it. I'd like to do my rear main seal and wouldn't mind taking care of that at the same time. I figure then I'll have it around to use whenever or loan out to club members.

Or you could just borrow mine. I went low price when I got it, so it's kind of a POS. But available if you need it. I'll be headed north this weekend so let me know if you're interested.

Much appreciate the offer, may take you up on it. How far north are you coming and which day?

Saturday and Brighton.

That should be easy to make happen. I probably need to go down to Brighton on Saturday anyway. Let me touch base with the wife. Should be pretty flexible.

Sounds good. I'll pack it for the trip anyway and if it happens it happens. You can text or call to let me know if you are going to make it. My number is in the members only section.

Hey. If you havn't already pulled the x-case and you need another body there, give me a call. I wont be able to offer advice but I'd like to see it done.

I may take you up on that. I had a guy up in Elizabeth contact me to let me know he has a few, so it'll depend partly on how much he wants for it. I'm thinking seriously about pulling the transmission at the same time to check the clutch and replace the rear main seal on my 302, as it (or something else that would drip thinninsh oil from the bellhousing) is leaking a drop every minute or two.

And so it begins. Once you get the rear main done, you'll see how easy it would be to pull the motor and clean it up. Then you'll think "man, I could just bolt on that EFI stuff now while the motor is out." And then you'll think about how you could just clean up the engine bay while you are waiting on that new harness to come in....

Trust me, my brain has already gone down that slippery slope. I really want to drive it for a change, so hopefully that'll provide some motivation to not go too far.

Don't do it, the xfer case back in and drive drive drive...