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NP-435 Swap

From 1983 Ford Bronco “That dirty old truck” — documented by Steve83.

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1983 Ford Bronco - I wore out my first trans when I lived in Louisiana, and I swapped in a used one from a ~'78 F250 4WD. It has started popping out of R unde… 1983 Ford Bronco - It had ~1/2" of mud caked on all over the case, so I scraped most of it off. The pile on the ground is only from this side. 1983 Ford Bronco - This is the 3rd one going in. See this image for decoding: [url=http://www.supermotors.net/registry/media/72317] http://www.supermotors.net… 1983 Ford Bronco - This is the 2nd one coming out. It replaced the 1st one when I lived in Louisiana, and it came from a ~'78 F250. See this image for decodin… 1983 Ford Bronco - This is a close-up of a rusty NP-435 transmission, likely for a truck or SUV. 1983 Ford Bronco - Service part number E4TA-7003-RA Transmission NP-435, 4WD reman The switch is for the reverse lights. 1983 Ford Bronco - My first step was to pull the boot. Just 4 screws. The floor cover is butchered because it's from a '94 F150 Xcab. 1983 Ford Bronco - Push down HARD on the retainer and turn it CCW to release. 1983 Ford Bronco - Then let it pop up and the shifter can come out. 1983 Ford Bronco - Make SURE the trans is in N before doing this, or it'll be tricky getting the shifter back in later. 1983 Ford Bronco - I pounded this cap onto the transmission to keep any dirt from falling in as I removed it. 1983 Ford Bronco - I didn't want a bunch of jack stands in my way, so I only used 2 to lift the truck ~6". Since all 4 wheels are still on the ground, it… 1983 Ford Bronco - Next, I dropped the skid plate, t-case shift linkage, & driveshafts. 1983 Ford Bronco - When the t-case separates from the transmission extension, oil will dump out, so be prepared with a big drip pan, and a CLOSED mouth. For c… 1983 Ford Bronco - NP-208F The stud just to the R of the yoke is the shifter shaft, and the single post above it is the range switch that turns on the light o… 1983 Ford Bronco - NP-208F 1983 Ford Bronco - I jammed the shifter up throught the boot to keep it out of the way. 1983 Ford Bronco - The upper 2 bolts (yellow) only need to be loosened. There's not enough room to remove them anyway. 1983 Ford Bronco - With the weight off the crossmember and the two 3/4" transmission bolts removed, the crossmember can be slid backward and rotated out of th… 1983 Ford Bronco - Since it was about to rain anyway and I needed a break, I decided to wash it before handling it. I really should have done this yesterday e… 1983 Ford Bronco - The underside of a vehicle is shown with a soapy transmission and exhaust system. 1983 Ford Bronco - I bought these before I started. Prices are written on the boxes. 1983 Ford Bronco - After rinsing, I let it dry and then removed the 4 mounting bolts. It's easier & lighter without the bellhousing attached, but the engine s… 1983 Ford Bronco - After a deep breath, I lifted the transmission, pulled the jack out, pulled the transmission backward, and then lowered it onto the wood th… 1983 Ford Bronco - Ya gotta be REAL careful! Putting it back up there without a trans jack is even LESS fun... 1983 Ford Bronco - With the truck up, it barely cleared the frame, but its (almost) flat bottom allows it to stand. 1983 Ford Bronco - The dirty one has been popping out of Reverse, so I'm swapping in the clean one temporarily, but I might have removed too many of the input… 1983 Ford Bronco - The main case of an NP435 is 10 13/16" front-to-back across the mounting surfaces; the 4WD extension is 8". 1983 Ford Bronco - Comparison of two manual transmissions, highlighting differences in appearance and features. 1983 Ford Bronco - It's barely visible, but the 15795 extension incorporates a dam to keep most of the transmission oil away from the t-case input seal. The 1… 1983 Ford Bronco - While the transmission was down, I decided to inspect the clutch, which was worn down & starting to slip. 1983 Ford Bronco - I also noticed some rust on the tip of the input shaft, and I discovered that I hadn't put any grease in the pilot last time. 1983 Ford Bronco - Since I didn't have a pilot bearing puller, I removed the flywheel to keep the grease off of it. The upper blue is a coolant bore plug; the… 1983 Ford Bronco - After packing the old pilot with grease, I found a steel rod that barely fit and a LARGE hammer. When the rod is driven in, the grease push… 1983 Ford Bronco - After a few tries, it was out. 1983 Ford Bronco - The last thing is to pull the rear main, which can be done with a small flathead screwdriver. It's not very tight. To improve the seal betw… 1983 Ford Bronco - In the bellhousing, I found the remains of the last starter I had to replace. 1983 Ford Bronco - I decided to keep the extension with the dam, and the gasket was shot, so I made a new one. 1983 Ford Bronco - Neutral 1983 Ford Bronco - Reverse 1983 Ford Bronco - 1st gear 1983 Ford Bronco - 2nd gear 1983 Ford Bronco - 3rd gear 1983 Ford Bronco - 4th gear 1983 Ford Bronco - NP 435 Identification 1983 Ford Bronco - Master Rebuild Kit AGP435 (BK127WS) Shortly after installing the 3rd trans, I realized I had taken out too many of the input bearing shims,… 1983 Ford Bronco - Rebuilding the New Process 435 IF THE IMAGE IS TOO SMALL, click it. [url=http://www.supermotors.net/registry/media/519172] http://www.super… 1983 Ford Bronco - I've decided to rebuild this one first since I know it needs a lot of work. I picked up another used one that should be OK to drive on for… 1983 Ford Bronco - This is the 4th trans going in. The 2nd will get rebuilt first; then the 3rd. If this one has any problems, I'll rebuild it, too. 1983 Ford Bronco - Powdercoated Shifter I still have to brush the coating out of the splines, and buy a new boot & retainer cap, but this looks a LOT better t… 1983 Ford Bronco - Old Manual Transmissions