1. Preparation:
* Safety First: Disconnect the negative battery terminal. Use jack stands to securely support the Bronco. Wear safety glasses and gloves.
* Gather Tools and Parts: You'll need jack stands, a wrench set (metric and standard), sockets, a torque wrench, a transmission jack or engine hoist (highly recommended), a drain pan, a transfer case specific to your Bronco (ensure it's the correct model), new gaskets and seals, possibly new bolts, and penetrating oil.
* Consult a Repair Manual: This is crucial! Your year and model will have specific procedures and torque specifications. Using the wrong torque can easily damage components.
* Fluid Collection: Have containers ready to catch the transmission and transfer case fluids.
2. Removal Process:
* Drain Transfer Case Fluid: Locate the drain plug on the bottom of the transfer case and carefully drain the fluid into your container.
* Disconnect Driveshafts: Disconnect the front and rear driveshafts from the transfer case. This often involves removing bolts and u-joints.
* Disconnect Linkage: Disconnect the linkage that controls the transfer case shifter.
* Disconnect Wiring (If Applicable): Some models may have electrical connections to the transfer case (e.g., for speed sensors). Disconnect these carefully.
* Support the Transmission: This is critical. Use a transmission jack or engine hoist to support the transmission and prevent it from dropping when you remove the transfer case.
* Remove Transfer Case Bolts: Locate and remove the bolts securing the transfer case to the transmission. These are usually located around the perimeter of the mating surface.
* Separate Transfer Case and Transmission: Carefully separate the transfer case from the transmission. It may be stiff due to the gasket. Use a pry bar carefully and evenly to avoid damage.
* Remove Transfer Case: Carefully lower the transfer case using your transmission jack or engine hoist.
3. Installation Process:
* Inspect Parts: Before installing the new transfer case, inspect the input and output shafts on both the transfer case and transmission for any damage. Clean both mating surfaces thoroughly.
* Install New Gaskets and Seals: Install new gaskets and seals on the transfer case and transmission mating surfaces according to the repair manual.
* Install Transfer Case: Carefully align the new transfer case with the transmission and bolt it in place using the correct torque specification from your repair manual.
* Reconnect Driveshafts: Reconnect the front and rear driveshafts.
* Reconnect Linkage and Wiring: Reconnect the shifter linkage and any electrical connectors.
* Fill with Fluid: Fill the transfer case with the correct type and amount of transfer case fluid (consult your repair manual).
* Re-install Battery Terminal: Re-connect the negative battery terminal.
4. Post-Installation:
* Check for Leaks: Inspect the transfer case and transmission for any leaks.
* Test Operation: Test the transfer case in all positions (2WD, 4WD High, 4WD Low) to ensure proper operation.
* Check Fluid Levels: Check the fluid level in the transfer case and top it off as needed.
Important Considerations:
* Professional Assistance: This is a complex repair. If you're not comfortable with this type of work, consider taking it to a qualified mechanic. Improper installation can lead to serious damage to your vehicle.
* Correct Parts: Ensure you're using the correct transfer case for your specific Bronco model and year.
* Torque Specifications: Always use the correct torque specifications from your repair manual. Over-tightening or under-tightening bolts can cause damage.
This information is for guidance only. Always consult a repair manual specific to your 1978 Ford Bronco for detailed instructions and torque specifications. Safety should be your top priority.
