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343 hits | 140.25 KB | Posted: 10/4/12
Picked this running truck up for $300.

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256 hits | 103.76 KB | Posted: 11/8/12
Pulling the engine out of the parts truck.

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303 hits | 48.02 KB | Posted: 11/8/12
It's visible how long it took me to get the engine from the truck to the back of my Bronco. The pre...

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322 hits | 157.43 KB | Posted: 10/4/12
After the drive shafts were out, the first major component I removed was the transfer case.

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335 hits | 138.79 KB | Posted: 10/4/12
Next out was the transmission and tail shaft. The shifter is a spring loaded setup where you have t...

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338 hits | 65.26 KB | Posted: 10/4/12
With the transmission, transfer case, and mat removed, next up was the floor pan.

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302 hits | 66.71 KB | Posted: 10/4/12
Not easy to remove. The bolts were simple enough, but it's glued on with some pretty heavy duty sea...

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322 hits | 104.05 KB | Posted: 10/4/12

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306 hits | 83.47 KB | Posted: 10/4/12
Loading parts up in my Bronco to take home. The truck is at my brother's house.

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314 hits | 80.66 KB | Posted: 10/4/12

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348 hits | 75.04 KB | Posted: 10/4/12
While walking back and forth from the truck to the Bronco, a random passerby crawled in and made him...

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322 hits | 109.34 KB | Posted: 11/8/12
Transmission on the back of the Bronco. It's tall.

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337 hits | 115.82 KB | Posted: 10/4/12
Tools all set up and ready for the big project.

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405 hits | 119.95 KB | Posted: 11/8/12
Removing the clackity clackity engine. Not sure what it's issue was (it had great compression, ran ...

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299 hits | 116.71 KB | Posted: 10/4/12
Home and ready to go in.

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301 hits | 139.23 KB | Posted: 10/4/12
Pulled the cover off to check out the gears. Made the mistake of not checking to be sure it was in ...

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358 hits | 100.74 KB | Posted: 10/4/12

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478 hits | 59.69 KB | Posted: 10/4/12
The shifter for the SROD is a bit easier to remove. Just two bolts and none of the difficult spring...

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447 hits | 79.84 KB | Posted: 10/4/12
Shifter and boots removed.

This picture also shows the difference between the SROD and NP435 setup....

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320 hits | 86.06 KB | Posted: 10/4/12
Old transfer case removed from the Bronco. The chain was starting to slip in this one so, for now, ...

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381 hits | 133.48 KB | Posted: 10/4/12
The SROD is out. A very small and light weight transmission. I used the transmission jack I bought...

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320 hits | 76.72 KB | Posted: 10/4/12
The hydraulic bell housing. I could have left my mechanical clutch linkage in place and just bolted...

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291 hits | 76.81 KB | Posted: 10/4/12

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311 hits | 92.37 KB | Posted: 10/4/12
The teeth look nice and clean. No chips, and everything moves smoothly.

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262 hits | 60.63 KB | Posted: 10/4/12
Disconnected the transfer case from the transmission. First time I've ever taken it off, and the fi...

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240 hits | 42.71 KB | Posted: 10/4/12
Lowering the transfer case with the jack.

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275 hits | 68.69 KB | Posted: 10/4/12
A transmission jack is a HUGE HUGE plus in this project. I don't recommend doing it without one. L...

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291 hits | 85.18 KB | Posted: 10/4/12
The truck transfer case. I quickly realized that the tailshafts of the truck and Bronco transfer ca...

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359 hits | 79.63 KB | Posted: 10/4/12
The mechanical vs. the hydraulic bell housing.

Not much difference except that the mechanical just ...

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340 hits | 89.08 KB | Posted: 10/4/12
Another shot of the SROD. I couldn't figure out how to remove the tail shaft. Since the shifter is...

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297 hits | 96.95 KB | Posted: 10/4/12
The broken transmission mounts.

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291 hits | 82.64 KB | Posted: 10/4/12
Just finished taking the engine out.

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466 hits | 78.5 KB | Posted: 10/4/12
Thought this was a cool picture of a straight through shot of the entire drive train missing.

Can s...

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333 hits | 91.4 KB | Posted: 10/4/12
The size difference between the SROD and NP435 was crazy. I imagine the large gears necessary for t...

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264 hits | 93.06 KB | Posted: 10/4/12

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250 hits | 73.22 KB | Posted: 10/4/12
Getting the NP435 ready to go in.

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441 hits | 75.8 KB | Posted: 10/4/12
The NP435 is MUCH taller than the SROD, so I jacked up the front of the Bronco to make room to slide...

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281 hits | 73.41 KB | Posted: 10/4/12
Getting the transmission into place to go up. I didn't want to mess with the crossmember (they're R...

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297 hits | 79.34 KB | Posted: 10/4/12
The transmission wouldn't fully go into place with the floor pan on, so I had to switch jobs for a f...

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303 hits | 76.22 KB | Posted: 10/4/12
Transmission bolted to the engine and hanging on its own strength.

A little deceiving in this pictu...

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234 hits | 82.87 KB | Posted: 10/4/12
I'm not one that's much for cleaning stuff up unless it's a mating surface. The exterior is just go...

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291 hits | 79.57 KB | Posted: 10/4/12

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368 hits | 67.02 KB | Posted: 10/4/12
Tailshaft housing is now bolted on to the transmission, transmission and bellhousing are now bolted ...

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276 hits | 41.67 KB | Posted: 10/4/12

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344 hits | 82.57 KB | Posted: 10/4/12
Time to swap the tail housings on the transfer case.

I hadn't been thinking, but as soon as I remov...

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319 hits | 74.39 KB | Posted: 10/4/12
Would be a great time to change out the internal speedometer ring gear if I needed to.

For what it'...

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254 hits | 55.38 KB | Posted: 10/4/12

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254 hits | 87.03 KB | Posted: 10/4/12
The gasket that goes between the transmission and transfer case (the circle in the lower right) was ...

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240 hits | 87.13 KB | Posted: 10/4/12

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247 hits | 78.39 KB | Posted: 10/4/12

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304 hits | 80.37 KB | Posted: 10/4/12
This large C Clip is the ONLY thing holding the chain, gears, and tailshaft in the case once the cov...

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296 hits | 69.99 KB | Posted: 10/4/12
After the C clip was removed (a big one, so kind of a pain without the proper tool), everything else...

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248 hits | 76.93 KB | Posted: 10/4/12
The chain has NO lateral movement in it, so once the clip is off, you have to slide both gears on th...

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228 hits | 82.95 KB | Posted: 10/4/12
The other end of the chain, with the tailshaft. It lifted right out and there was nothing holding i...

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201 hits | 82.53 KB | Posted: 10/4/12

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227 hits | 80.22 KB | Posted: 10/4/12
When putting them back in, the only thing to check is that everything in the hole is lined up. Ther...

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250 hits | 70.43 KB | Posted: 10/4/12
Both cases had this provision, but only the transfer case that was on my Bronco still had the magnet...

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242 hits | 64.63 KB | Posted: 10/4/12
Magnet missing from the truck transfer case.

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254 hits | 79.44 KB | Posted: 10/4/12
This was the biggest noticeable difference between the transfer cases. The TC in the '81 Bronco was...

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249 hits | 75 KB | Posted: 10/4/12
This is the different disc for the NP208F. No idea what the difference does.

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239 hits | 89.75 KB | Posted: 10/4/12
The shorter shaft is put in. Have to slide the chain around both gears and then drop both sides in ...

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237 hits | 87.94 KB | Posted: 10/4/12
There is no gasket between the two sides of the casing, just a layer of silicone. I scraped off the...

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271 hits | 88.21 KB | Posted: 10/4/12

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234 hits | 87.28 KB | Posted: 10/4/12
The Bronco and F150 tailshafts have a different end on them. The Bronco has a yolk that bolts to it...

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241 hits | 54.98 KB | Posted: 10/4/12
I put the new floor pan in place and am going to swap over the front floor mat from the truck. Fort...

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296 hits | 65.54 KB | Posted: 10/4/12
The white insulation on the driver's side is some I put in last year after replacing the fully rotte...

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357 hits | 70.94 KB | Posted: 10/4/12
I trimmed the back end of the truck mat and the front of the Bronco mat so that they'd meet right in...

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240 hits | 82.7 KB | Posted: 10/4/12
Simple Green household cleaner worked wonders to clean up the shifter boots. They were covered in c...

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244 hits | 59.21 KB | Posted: 10/4/12
Time to put in the hydraulic clutch master cylinder. I've been nervous about this part since it has...

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246 hits | 55.07 KB | Posted: 10/4/12
The gasket from the master cylinder made a great template.

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276 hits | 70.07 KB | Posted: 10/4/12
Master cylinder ready to go in.

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269 hits | 76.68 KB | Posted: 10/4/12
I needed to move the brake booster out of the way to get the drill in. A circular metal saw drill b...

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281 hits | 61.69 KB | Posted: 10/4/12
Ahhh..... Master cylinder is in.

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249 hits | 79.02 KB | Posted: 10/4/12

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247 hits | 88.58 KB | Posted: 10/4/12
The clutch and brake pedals, ready to go back in.

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231 hits | 65.96 KB | Posted: 10/22/12
My old clutch is on the left while the F-150s clutch is on the right. Much sharper and cleaner hole...

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190 hits | 61.83 KB | Posted: 10/22/12

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217 hits | 68.13 KB | Posted: 10/22/12

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230 hits | 64.02 KB | Posted: 10/22/12
The mechanical and hydraulic clutch arms have different angles. The hydraulic clutch is back furthe...

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235 hits | 65.28 KB | Posted: 10/4/12
The mechanical clutch rod had a boxed end on both ends and allowed for no adjustment of any kind.

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290 hits | 97.64 KB | Posted: 10/4/12
The hydraulic clutch had a splined end that goes through the hole on the clutch arm. The splined en...

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241 hits | 73.38 KB | Posted: 10/22/12
Once the pedals and rod are in, the clutch spring needs to be put back in. Unless you're The Hulk, ...

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250 hits | 71.47 KB | Posted: 10/22/12
(I tried zip ties but they didn't work)

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235 hits | 73.14 KB | Posted: 10/22/12
I first tried wiring only one side, but that didn't work either.

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309 hits | 42.04 KB | Posted: 10/22/12
After both sides were wired, it went back in easily.

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242 hits | 58.37 KB | Posted: 10/22/12
Back in place. One end goes into a slot on the pedal bracket and the other end goes into the fork o...

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231 hits | 63.62 KB | Posted: 10/22/12
Once it was in place, I used wire cutters to cut the wires off the spring.

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231 hits | 74.1 KB | Posted: 10/4/12
The splined end of the clutch rod.

After I tried it this way, the rod twisted the splines out of th...

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263 hits | 58.89 KB | Posted: 10/4/12
The clutch arm lined up nicely with the master cylinder.

I need to get new bushings for the arm. T...

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472 hits | 87.64 KB | Posted: 12/21/12
Well, after a few weeks, the throwout bearing seized. Wish I would have thought to replace it when ...

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247 hits | 73.71 KB | Posted: 12/21/12

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221 hits | 80.03 KB | Posted: 12/21/12
Good thing I decided to pull out the engine to do the clutch, I found out it had a blown head gasket...

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300 hits | 83.56 KB | Posted: 12/21/12
Found an excellent technique for torquing down the flywheel and clutch. Put the water pump pulley o...

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225 hits | 74.27 KB | Posted: 12/21/12
New flywheel bolted down.
The old one had massive cracks in it so it was no good.

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257 hits | 99.47 KB | Posted: 12/21/12
New clutch and pressure plate tightened down and installed.

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254 hits | 90.6 KB | Posted: 12/21/12