Hi,
This is long but please read. I was wondering if anyone had any suggestions on what I should do.
I have a 87 Bronco 300 6 cyl. EFI, 4 spd, 4:56 gears front, and back, ARB locker in back, and a detroit locker in front. It has 33/12.50 TSLs on it with a stock lift. The transfercase is a BW 1356 manual shift. Anyhow here is how my trouble started. I was driving it home about a week ago, and I had the cruise set at 75. The speedometer is off so I was actually going about 65. Anyhow all of a sudden it just died. I was about 10 miles from home, and a guy with his truck came by, and pulled us home. I forgot to put the transfer case into neutral. It pulled fine, and no trouble. The fastest he pulled us was 55 mph. Once it was at home I started checking for any problems as to why it wouldn't run. It wasn't getting any spark. After replaiceing a bunch of electrical parts I came to figure that it was the timing gear. I didn't have the time to fix it myself so I decided to have my mechanic do it for me. So now I have to pull it back 10 miles to where my mechanics shop is. This time I remembered to put the transfercase into neutral. Or at least I thought it was neutral. I may have accidentally hit 4LOW. I'm not sure. Anyhow we started to pull it, and I thought it was pulling kinda hard, but I wasn't sure We got about 6 miles out, and I notice a very quiet grinding noise. Kinda like a bicycle chair noise. The fastest he pulled me was 50 mph. About 1 mile further it is getting louder, and I'm starting to smell something burning or something. Then all of a sudden I'm freeking out because I notice that there is smoke coming from both the shifter boot, and the transfercase shift boot. I hit the brakes imediately, and as were slowing to a stop I hear this poosh, and a little poof of smoke came out of the transmission shift boot. After that when we were comeing to a complete stop I heard a clanking, as if the transmission was in gear or something. The tires were catching. I had no clue what the hell had just happend. The guy who was pulling me asked me if I had the clutch pedal pushed in. I said no, he said that you are supposed to. I said that I had never heard of that. So then the rest of the 4 miles he pulled me to my mechanic I held the clutch in, and he said it pulled a lot easier. Once we got to my mechanic's shop I tryed shifting the transfercase, and it shifted fine, then I tryed shifting the transmission, and It shifted fine into 1st, couldn't get 2nd or 3rd, I got 4th, and I couldn't get it back out of 4th. My mechanic changed the timeing gear for me, and got it running. He said he got the transmission working, but the transfercase is leaking fluid. He diddn't look at the transfer case too close, but he says he thinks the case is cracked.
Now I don't know what to do. I don't have $400. to spend on a new case, and everyone I talked to says that the transfercase I get has to be the EXACT same as the one it has. I was wondering if anyone had any suggestions. This has been a nightmare for me.
Please help me out any way you can.
Thanks,
Ezra