BroncoII4x4.com

And now for something completely different. A friend gave me a 87 B2 parts truck that has a low mileage 5spd manual and associated hardware still in it. I didn't realize that the 2WD had a dummy transfer case in them. I'll take pictures and document the swap.

then your all set them

Pulled the 5spd, pedal sector, master cylinder, flywheel, clutch, and forgot the cross member. But, hey, ain't that what a welding machine's for? Got everything put in the shop for now. I want to get a new release bearing assembly, clutch disc, pilot bearing, and some other stuff before I do the install.

According to a friend's parts interchange book, the drive shafts are different. But I don't care since I'll be using the original transfer case. As long as the TC bolts up I'll be fine. Also found out that my 5spd is a Mitsubishi FM 145.

18 Days later and here's where I am:


Finally pulled the A4LD and transfer case. Got the transfer case on the FM145 5spd and installed the new slave cylinder. Everything bolted together fine. There is a 3 inch difference in length between the automatic and manual. The rear driveshaft will still work due to the slip joint without modification. I will have to go back to the junkyard for the front drive shaft as the one I have is too long ( I was told it would be).
The transfer case linkage was still on the manual when I pulled it so everything lined up good.
Tomorrow I'll pull the flex plate, trans cooler lines, and kickdown rod. Hopefully I'll get the flywheel, clutch, and pedals done tomorrow as well. I need a gasket to go between the FM145 and TC and I would like to change the bushings in the shift lever.

More to come

you sure theres gonna be enough spline for the rear shaft?? 3in is quite abit

could you measure your 145?? from the bell(where it bolts to the block) to where the t-case bolts on.i dont have that one

I measured between 26 5/8 & 26 3/4. Hard to tell at an angle. Also measured the drive shaft splines. You may be onto something. 3 inches looks like a lot to make up. I may get a spacer machined to go between the output yoke and driveshaft out of steel. There are a few places in Baton Rouge who can build driveshafts if I don't have another option.

I need a gasket to go between the FM145 and TC and I would like to change the bushings in the shift lever.

Can't find either one online. I'll have to try Ford Monday. I can probably make a gasket for the transfer case, but the shift bushing will be a little tricky.

i use some permatex

cajun66 wrote:

I need a gasket to go between the FM145 and TC and I would like to change the bushings in the shift lever.

Can't find either one online. I'll have to try Ford Monday. I can probably make a gasket for the transfer case, but the shift bushing will be a little tricky.

try here
http://www.greensalescompany.com/

I have the permatex. I just need to find the part # for the bushing.

the part number for the shifter

E6TZ 7210-C

Can't find it at either website.

Green Sales doesn't stock it. Can't figure out how to search txexchange. Google search turned up a bunch of dead ends. Biggest problem is I'm not internet savy. Me and the mosquitos are still on dialup even. I'll call a few sources from work tomorrow. Worst case I try to carve one out of poly on the CNC.