What is the torque spec for the transfer case adapter bolts?

The six 3/8x16x1.50 bolts (part 383890-S-100) are torqued to 25-35 ft-lbs, and the 9/16-12x3.25 bolt is torqued to 55-65 ft-lbs.

What does the shifter alignment pin do?

The shifter alignment pin positions the shifter in neutral. It is to be removed after assembly of the shift rods and attaching components to the shifter assembly has been completed.

How should the transfer case levers be set when installing or adjusting the shifter linkage?

The transfer case levers should be placed in the neutral and unlock positions for shifter linkage installation or adjustments.

What are the part numbers for the transfer case assembly and transmission adapter?

The transfer case assembly is 7A195 and the transmission adapter is 7A039, with gasket 7086 between them.

What torque applies to the transfer case rod nut and shifter mounting bolts?

The transfer case rod nut is torqued to 15-20 ft-lbs; shifter assembly bolts are 12-18 ft-lbs, and another bolt is 70-90 ft.

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1978 Ford Bronco NP203 Transfer Case & Shifter Linkage Exploded Diagram

Exploded diagram of transfer case, shifter, adapter and mounting hardware with torque specs

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Exploded parts breakdown of the transfer case and shifter assembly with adapter, brackets and torque specifications.

AI caption March 2006 · Photo 336 of 529

This document is an exploded parts and installation diagram for a transfer case and its shifter linkage, uploaded as applying to a 1978 Ford Bronco with the NP203 transfer case. It contains four views: a main view showing the transmission and transfer case assembly installed under the vehicle floor pan; a view in the direction of arrow Y showing the transfer case assembly, shifter assembly, shifter alignment pin (which positions the shifter in neutral), and mounting bolts with torque values (12-18 ft-lbs and 70-90 ft); a view in the direction of arrow X detailing the shift linkage components including ball assembly, jam nut, retainers, flat washer, adjusting stud, transfer case rod, and nut torqued to 15-20 ft-lbs; and an exploded assembly view showing the transmission adapter (7A039), gasket (7086), transfer case assembly (7A195), brackets (7A444 and 7A051), insulators (6068 and 6A061), spacer (6A027), washer (384525-S2), and associated fasteners with torque specifications (25-35, 55-65, and 30-40 ft-lbs). Notes explain that the transfer case levers must be placed in neutral and unlock positions for shifter linkage installation or adjustment, and that the shifter alignment pin is removed after shift rod assembly is complete.

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Frequently asked questions

What is the torque spec for the transfer case adapter bolts?: The six 3/8x16x1.50 bolts (part 383890-S-100) are torqued to 25-35 ft-lbs, and the 9/16-12x3.25 bolt is torqued to 55-65 ft-lbs.
What does the shifter alignment pin do?: The shifter alignment pin positions the shifter in neutral. It is to be removed after assembly of the shift rods and attaching components to the shifter assembly has been completed.
How should the transfer case levers be set when installing or adjusting the shifter linkage?: The transfer case levers should be placed in the neutral and unlock positions for shifter linkage installation or adjustments.
What are the part numbers for the transfer case assembly and transmission adapter?: The transfer case assembly is 7A195 and the transmission adapter is 7A039, with gasket 7086 between them.
What torque applies to the transfer case rod nut and shifter mounting bolts?: The transfer case rod nut is torqued to 15-20 ft-lbs; shifter assembly bolts are 12-18 ft-lbs, and another bolt is 70-90 ft.