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Mar 18, 2015 | 11:16 PM

madatengineers

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Hey, folks. I'm new here. Not sure what I'm doing, so I'll just go for it. I've got a 96 F350 4x4 with a 351. Recently, I let off the gas and 'BOOM', my transfer case snapped off (I suspect the rear joint piled up). I was in 2wd with front hubs unlocked so transfer case just fell onto skid plate. The yoke on transfer case broke sending my rear driveshaft into pave. I've got a ZFS547 tranny in it. The rear extension housing is broken. I've been reading and reading to no avail. Question 1: can the rear extension housing be replaced without removing the tranny? Question 2: a buddy of mine dropped off a ZFS542 with bad guts. The part #'s on the extension cases are different, but look the same. Are they the same case? Thanks in advance.

Mar 21, 2015 | 08:12 PM

IB Tim

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From: 3rd Rock

Moved to help you receive a better answer...enjoy FTE

Mar 22, 2015 | 06:11 AM

tjc transport

i ain't rite

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From: Marlboro Mental Hospital.

welcome to FTE.
if the piece you are talking about is the adapter that bolts to the rear of the trans, and the front of the t-case, yes you can swap it without removing the trans.
have the T-case checked closely, when mine did that the pump seized and destroyed the t-case. i had to get a new one.

Mar 22, 2015 | 07:17 AM

bashby

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From: Charles Town, W bygod Va

I'm not sure what adapter Tom is talking about. The transfer case bolts directly to the transmission and the rear half of the case can not be replaced without removing and disassembling the trans. There is a really good writeup on rebuilding a zf5 on oilburners.net.

Mar 22, 2015 | 07:39 AM

tjc transport

i ain't rite

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From: Marlboro Mental Hospital.

the transfer case bolts to an extension that bolts to the back of the ZF trans, and has the trans/transfer case mount on it.
the extension is not used on a F-superduty, the parking brake assembly bolts directly to the trans where the extension would.

at least that is how all my 88 to 91 trucks were.

Mar 22, 2015 | 08:24 AM

Diesel_Brad

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From: Gilbert, PA

The s47 and s42 use different housings and NOT interchangeable

As for the "extension" housing. It IS the REAR housing of the trans. I don't think you can just pull it off and slide another on

Mar 22, 2015 | 09:32 AM

tjc transport

i ain't rite

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From: Marlboro Mental Hospital.

thinking about it just now, i was wrong. it is the automatic that has the separate extension housing. the ZF has the extension as the back of the trans.