How do I remove the np205 Transfer case?

[Phil76]

We're getting ready to pull the 390 out of our 76 Bronco, and I need to remove the transfer case and tranny first. This is my first 4wd vehicle so I want to make sure we do things right. What setting should the TC be in for removal? 4h, 4l, n, of 2h What about the tranny (4sp np435)? We've got a transmission jack to hopefully make the process easier. Should it slide back fairly easily, or am I going to have to whack the crap out of it to get it out? I'd like to get this done tomorrow, so I can spend monday getting the engine out. Thanks

 

[Bully Bob]

Hi Phil....

I think I would pull the eng. 1st., with a jack holding up trannie. (back of trannie/transfer is what holds up the rear of eng.) Then you have 1/2 the job of removing tran/transf done.

Leave tran/transf bolted together & lower as one unit.

"Should it slide back fairly easily, or am I going to have to whack the crap out of it to get it out?"

With the eng. out...this is not an issue., but no...should slide right out if not in a bind.

Don't seperate tran/transf 'til you read up on it.

The 3sp needs to be in 1st. gear to keep roller bearings from falling into case (during seperation fr. adaptor) don't know 'bout the 4sp.

Also., during seperation., you have no choice as the input shaft fr. trannie (adaptor) pulls out of the transfer....the roller bearings will likely fall into the transfer case.

It's no biggie .. i.e. ya just need to know what's happening so as to re-assemble correctly. They're easy to recover with a magnet.

Draining all the oil 1st. helps.

This is all assuming you're going to work on the tran/transf ....if not. what gear they're in doesn't matter if not seperating.

Should you need to sep. transfer... it doesn't matter what gear it's in for disassembly or assembly