where the driveshaft goes into the transfer case use smoothing to put against it like a brass rod or straight crow bar nad try to drive it backwards with a hammer towords the transfer case thats wht i had to do to change my front u jointsit will go towards the t case it may take some work

wayne

 

Getting back to changing the starter on my 1993 aerostar 4.0l engine, automatic xlt 7 passenger electric 4 wheel drive.

The driveshaft right below the starter has four bolts on the forward end of the driveshaft. The back end of the driveshaft going into the transfer case has a rubber boot over the splines plus a metal over shield over a nut before going into the transfer case does that nut need loosing before hammering that driveshaft back into the transfer case and if so what kind of wrench do I need to lossen that nut. Because the nut is recessed under a metal cover.

 

Running into the trouble of not being able to slide driveshaft back far enough to get it to the side. I can try to force it don't want to cause more damage. I like my Broncos and full size trucks! This Areostar was a giveaway because it didn't run. A new fuel pump and a mass air flow sensor on the 4.0L AWD '94. It almost went to the scrapyard, till I needed wheels.

 

I think one trick is to remove the bolts holding the transmission to the crossmember and jack up the transfer case slightly. You should not have to jack it up so much that you have to remove anything else, just enough to move the front of the driveshaft around to drop it. Then you should be able to pull the shaft from the transfer case, after removing the clamp from the big end of the dust boot.

 

Victory at last. New starter installed and drive shaft reconnected battery hooked up. Turned the ignition to start and it fired right up. I guess it just didn't like 40 below zero temps.