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I picked up a 2002 V10 Excursion with a laundry list of deferred maintenance. So far I swapped out the fuel pump (scary but satisfying), fixed the leaky rear dif cover, and new spark plugs. Next was the u joints and leaky transfer case. When I twisted the driveshaft to observe the u joints, the transfer case actually moved! I marked and dropped the driveshaft, replaced the u joints, and took a good look at the transfercase. It appears the extension that mounts the transfercase to the tranny is broke near the bottom, where it bolts to the transfer case, not to mention every bolt into the transfercase was loose - real loose. It was dark - sorry for the cruddy pic, but is swapping the extension just removing the transfer case then unbolting the extension from the tranny & replacing it? Thoughts? Thank You
That don't look normal - transfercase to extension / tranny
Thats the transfer case to transmission marriage or adapter plate. Through the ford sponsor on this site you can get it for under $150.00 I was afraid of the weight & being able to lift it back into place, so i paid a transmission shop to do the work.
Right on - thank you for the info. So I have a new adapter ordered, and my plan is to pull off the transfer case today. What's weird is that it looks like there are no supports at all for the transfer case - just where it bolts to the adapter. Can that be right? It doesn't attach to the cross member, or anywhere on top...... Is this normal for the excursion?
Normal for most ford trucks anyway. After mine broke i was looking under a bunch of trucks and none of them had any other support, maybe because they flex/twist?
Really surprising all that weight being held by 6 bolts! No wonder they shake loose. I was missing a bolt and one was broke, so holding on by just 4. I built a brace on a Jack with 2x4's to support removing the transfer case and it worked perfectly. The hardest & most frustrating part was reaching up blindly to remove the bolts on top of the transfer case - very little room to get a wrench or socket up there but finally got it. With the case off and down I found the input seal is what was leaking so swapped that out (easy pry out with a chisel), and now I wait for the adapter.
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