Why is there no power to the axles when the transfer case is in Neutral?

In neutral, the drive gear turns the idler shaft and the high-speed gear that free-runs on the front output shaft, so no power can be delivered to either axle even when the transmission is in gear.

How does the transfer case provide speed reduction in 4L?

The shift lever pushes the two sliding gears back into engagement with the idler shaft low-speed gear teeth; power flows from the main drive gear to the idler drive gear and shaft, to the idler low-speed gear, then through the two sliding gears to their output shafts.

What happens in the 2H position?

The two sliding gears are pulled forward out of engagement with the idler shaft low-speed gear; the rear output sliding gear engages the clutch teeth of the main drive gear, locking the input shaft directly to the rear output shaft. Power goes to the rear axle without speed reduction, and the front axle receives no power.

Where are removal and disassembly procedures for this transfer case found?

Removal and Installation are on page 6-20; Major Repair Operations start on 6-21, with Disassembly on 6-21, Parts Repair or Replacement on 6-22, and Assembly on 6-23.

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Ford Bronco 2-Speed Transfer Case Description & Operation - Shop Manual Pg 6-19

Service manual page 6-19 describing 4-wheel drive transfer case operation with cutaway figure

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Service manual page covering 4-wheel drive transfer case description and operation with a cutaway gear train figure.

AI caption March 2006 · Photo 66 of 206

This is page 6-19 of a Ford shop manual, the opening page of Part 6-3 covering the 4-Wheel Drive Transfer Case for the Bronco. It begins with a table of contents for the part, listing Description and Operation (page 6-19), Removal and Installation (6-20), and Major Repair Operations including disassembly, parts repair or replacement, and assembly (6-21 through 6-23). The Description and Operation section explains that the Bronco uses a manually-shifted 2-speed transfer case with shift lever positions 4L (low gear, all wheels), N (Neutral), 2H (high gear, rear wheels), and 4H (high gear, all wheels). Detailed power-flow explanations are given for the Neutral, 4L, 2H, and (beginning of) 4H positions, describing how the input shaft, main drive gear, idler shaft gears, sliding gears, and output shafts interact in each mode. Figure 1 (illustration C 1599-A) shows the transfer case gear train in neutral with labeled components: main drive gear, rear output sliding gear, input shaft, rear output shaft, idler shaft drive gear, idler shaft low-speed gear, front output shaft, high-speed gear, and front output sliding gear. A reader learns how each shift position routes power and where each gear is located within the case.

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Frequently asked questions

What are the shift lever positions on the Bronco transfer case?: From front to rear: 4L (low gear, all wheels), N (Neutral), 2H (high gear, rear wheels), and 4H (high gear, all wheels).
Why is there no power to the axles when the transfer case is in Neutral?: In neutral, the drive gear turns the idler shaft and the high-speed gear that free-runs on the front output shaft, so no power can be delivered to either axle even when the transmission is in gear.
How does the transfer case provide speed reduction in 4L?: The shift lever pushes the two sliding gears back into engagement with the idler shaft low-speed gear teeth; power flows from the main drive gear to the idler drive gear and shaft, to the idler low-speed gear, then through the two sliding gears to their output shafts.
What happens in the 2H position?: The two sliding gears are pulled forward out of engagement with the idler shaft low-speed gear; the rear output sliding gear engages the clutch teeth of the main drive gear, locking the input shaft directly to the rear output shaft. Power goes to the rear axle without speed reduction, and the front axle receives no power.
Where are removal and disassembly procedures for this transfer case found?: Removal and Installation are on page 6-20; Major Repair Operations start on 6-21, with Disassembly on 6-21, Parts Repair or Replacement on 6-22, and Assembly on 6-23.