SOURCE: Ring gear needs to be replaced on the flywheel
I've removed and replaced many,many of those transmissions,as well as the automatic trans version,and the 2 wheel drive version where a "dummy" transfer case is still in place but 2 wheel drive only,but that's another story entirely.The transfer case shifter will interfere with removal making it impossible to remove without breakage.The first technical tip on the hydraulic line disconnect at the transmission is the white plastic.Locate where the hard plastic hydraulic line comes over from the body,to the transmission.The line goes from small to big,and is gold in color.The female receiver socket is the hydraulic slave cylinder.In between the two gold halves that are attached as one is a round,white piece of plastic.This white plastic is plunged,evenly,and gently,into the slave cylinder with either a couple of small pocket screwdrivers,or there is a tool available specifically for this.The transfer case is attached with 5 or 6 bolts that from the factory,took a 13mm socket to remove.The point of the excercise of removing the driveshafts and the transfer case is because reinstallation with everything in place WILL be impossible.There is also an issue with the exhaust head pipe or Y pipe on the V6 version.The EASIEST and LEAST frustrating way to remove is actually MORE work,but in the end you will have to do it anyways.First is to support the transmission with a floor jack or trans jack,then remove the transmission crossmember and mount,13 mm,18mm,and 19 mm bolts,both driveshafts,mark with a marker before removal,to index the driveshafts the same way they came out and prevent any possible vibrations.Disconnect the transfer case shifter,just let it lay there off to the side,or fasten it up out of the way with a bungee cord.Disconnect speedometer,remove transfer case.Some trans fluid can drain out if you haven't drained it already.There is a gasket between the trans and transfer case,and if not replaced,you will have a leak there when reinstalled.Remove the starter and any bolts attached to the engine plate at the front of the trans.The shifter bolts on the transmission can be removed either through the cab of the vehicle which involves removing the rubber shifter boot assembly,then accessing the 3 shifter bolts,they take either a 25 or 27 torx socket,it's been awhile since i've seen a Bornco 2.Some guys leave the torx bolts in place and opt to remove the 18mm nut they see at the shifter stub.The nut can be removed,and then the pin driven out the opposite direction,but this leaves a shifter stub,about 3 inches tall that also interferes with removal and installation.I just remove the 3 torx bolts from under the truck with a tool i've made,and leave the shifter and boot hanging in the trans tunnel..After all that it is time to remove the bellhousing bolts,which are 13mm head.I believe 6 of them.Trans should slide out now.Check crankshaft endplay as part of your inspection procedure.The crankshaft thrust bearing is more prone to wear on a manual trans vehicle.It isnt hard to do,and requires a relatively long pry bar.You can hook your pry bar in between the flywheel and engine oil pan,and GENTLY pry the flywheel backwards.Now remove pry bar,place pry bar in between flywheel and the floor pan,or the transmission tunnel,and pry the flywheel back,give it a quick firm shove,towards the front of the vehicle.Acceptable endplay of the crankshaft is minimum .006" to maximum .015" and unacceptable of around .020"and up.Endplay can be checked with a magnetic base,or clamp base,dial indicator.After the endplay check,remove the flywheel to visually inspect the ring gear.Look for stripped teeth,or teeth that are missing or damaged in any way.I have replaced many a Ford,GM and Jeep and others,flywheel ring gears.An oxy/acetylene torch is required to remove and reinstall a new ring gear.Set the torch on medium to hot heat,place the flywheel on a steel workbench,ring gear up,and start contacting the ring gear with the flame,and keep the torch moving in a circular direction until the ring gear has heated up low glowing red or barely red.Knock off the old ring gear with a hammer and punch.Reinstallation is directly the opposite.You can also opt for a new flywheel,with a new ring gear,or good used if you can find it.Good luck.
SOURCE: removing the right intermediate axle shaft
i can only guess it is a 3.0l 4v well as far as the axle goes, the rh outer half shaft seperates at the splines on the intermediate shaft.
the intermediate shaft is the solid shaft from the trans to a bearing support bracket and ends after that. it is externally splined.
the rh axleshaft , inner cv joint, is internally splined.
to remove the rh axleshaft, remove the rh wheel and splash shield.
removed the lower balljoint pichbolt and seperate the lower balljoint front the steering knuckle. take the axle nut off and using a large brass drift or hardwood, drive the axle out of the bearing-hub assembly. DO NOT DAMAGE THE THREADS. also use some lubricant on the axle nut dissasembly. after the outer axle end is free, using the same brass drift or other, hit the inner cv joint and drive it off the intermediate shaft. inspect the splines closely because these fail and cause a no-drive condition.
then the mounint bolts for the support bearing and pull the intermedate shaft out, you will loose some fluid.
SOURCE: I am changing the drivers side half shaft on a
use a pry bar and put it in between the trany and the axle and give it a pull,or use a hammer and a bar place bar against back side of axle and hit it with hammer to break free, theres a c clip on the end of the shaft that holds it in,
SOURCE: I want to replace my transfer case for a 2006 Ford
You need to raise the truck off all four wheels the remove the rear drive shaft then remove the front drive shaft .Next drain the fluid from the transfer case . next reinstall drain plug. Now use a jack and a flat piece of wood and slightly jack up un the bottom of the transmission to take the weight off the crossmember . Next remove the croosmember brace after removing that and supporting the transmission you can start removing the wiring and contols on the transfer case after dissconecting all that now you can remove the bolts from the transmission to the transfer case , remove all but one easy to get to lower one ( you choose) now start taking the last bolt out while holding the transfer to the transmission .( two people here helps) once you have removed the last bolt slide the transfer case back torwards the rear end some fluid may come out once you seperate these two be ready to catch it with a drain pan . you slide the transfer off the transmission out put shaft and it out . flow the step inreverse to install don't forget to refill the new transfer case with fluid and check the transmission fluid level once you have lowerd the truck back down.
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