I bought a motor, tranny, and transfercase for a 89 bronco to change out with my 91 f150 and i was looking and at the drive shaft hookup and they look alot diffrent and i was womdering if i am going to have to change the transfer case or is there a driveshaft that will work also my f150 is an ex cab
Install everything except for the driveshaft, measure and have the driveshaft shortened or lengthened as required, true up on lathe and reweld the yokes to match components. simple job for a good machine shop that specializes in custom work.
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Had one years ago and it turned out to be a collapsed lifter. it almost sound like a bearing was going out but the sound was coming from mid to top of the engine. Change them all if thats it. It is somewhat of a large job, Remove upper and lower intake and valve covers.
The best and easiest, and Probably the cheapest way is to find an old beat up 82-89 f150 that is 4x4 usually can be found cheap without motor or lots of body damage, reason for this is that you will need to buy a front end differential, as well as the driveline and transfercase, different transmission and possibly a shorter rear driveline, but if you buy the beat up non running 4x4 you can simply put your body and motor on the 4x4 frame and be done, I have done several this way and works very well, also much faster,easier and cheaper....
From 1990-1996 The C6 was replaced by the E4OD which was modified to include a fourth forward speed and electronic shift controls, replacing the hydraulic control mechanism of the C6.
The C6 works fine in your bronco.. Your friend will need a different transfer case!. i dont have the manual but this is my best guess. FOrd likes to make cars that have interchangeable parts. Like a 1999focus can interchange with 2007. as long as the liter and engine size are the same. In some cases. you will have to use different transfercase.
So you might be better off with a c6 transfer case or c4 for your friend.
91 to 93 can have the same 6 lug pattern. the 89 is strickly a 5 lug. The axles from the 89 will not fit in the 91 differential. Yes it would be easier on you to change out the whole thing and change it to a 5 lug truck. Good luck, from a Chrysler parts employee.
that box does engage the transfercase to 4x4,there is a small electric motor on the transfercase thats probably bad,try hitting it lightly with a hammer because just like an electric window motor it has brushes in it as well,but its possible that motor is shorting out causing it to draw alot from the charging system,at least my 1993 Ford Bronco did the same thing and thats what i replaced and now it works fine.