BG 1356 swap problems
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Junior User
Joined: May 2004
Posts: 55
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From: Cowtown
BG 1356 swap problems
I'm in the middle of swapping a manual shift 1356 in place of the electric shift model. The rear output yoke of the electric shift t-case wont fit on the manual shift. It only slides on about half an inch and wont go any further. Ive tried heating it and hammering but it wont budge. Are the output shafts different sizes? Both cases are out of 87-91 Broncos. I cant find another junkyard 1356 or an output yoke so im considering replacing the 1356 with the T-case from a 80-86 bronco. (lots are in junkyards) Will a case like this bolt up? Or should I just keep looking for another yoke for the 1356. Please help me 
Lead Driver
Joined: Sep 2002
Posts: 9,182
Likes: 12
From: Gateway to the West
Grogtronics made this discovery a few months back with a manual version from a newer truck than his. Somewhere in the late 80's-early 90's a switch was made and the output shaft on the BW-1356 cases changed diameter by about 0.020". Not much but enough to make the swap impossible without changing yokes and/or rear driveshafts. He relayed the info to me when I bought the manual case he had been trying to use. He and I were under the impression that the change may have taken place when Ford quit mounting the U-joint yoke directly to the output shaft and started using the flat flange assembly between the output shaft and the front double-cardon U-joint on the rear shaft. I suppose its possible that it may have been sooner.
Last edited by greystreak92; Nov 15, 2005 at 12:40 PM.
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Junior User
Joined: May 2004
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From: Cowtown
Jeez, I shoulda been more patient. The night I posted this I went out and hammered the hell out of the yoke and broke it. I thought I was just crazy thinking they could be different. The price for a new yoke was more than what I payed for the whole the T-case. So Ive already swapped in the NP 208 (I think) as it was even cheaper than a new yoke. I'll swap back to the 1356 when I find a junkyard yoke. Why wouldnt you go to the older style T-case anyway? Thanks for the info, you guys are really smart.
Tuned
Joined: Jul 2004
Posts: 476
Likes: 5
From: Delaware
Greystreak92, I just installed a Borg 1356 in my 91 Bronco. It came from an 88 Bronco and I put it in my 91 after I had the "bump" inside the 1988 case welded up as it would have worn thru in the near future and let the pump spin around. At least I caught it in time as that's the reason for removing the one from the 91. Both were manual shift transfer cases. The only difference was the shift lever on the 88 was bolted on the shaft and the one on the 91 was part of the shaft. I took the U-joint style yoke off and installed the flat flange yoke from my 91 case with no problems whatsoever. It slipped right on as easy as the earlier style.
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