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Long Time lurker, first post. My well used 08 F250 blew the chain in the transfer case and cracked the housing. Pulled another off of a 06 F250, both are NP 273f, only the assembly numbers vary old is "AB" new is "AG". No issues it seams untill... the aligning pin. New one has pin in the TC, old pin is stuck in the transmission side. Cant get either to budge. Thoughts?
My worst case solution is I grind both off and use the 8 bolts alone.
But yeah, I've always understood the pin just gives you "a break" when installing, I can't see how the bolts alone won't be enough as I wouldn't trust that pin to withstand any substantial torque anyhow.
If you wanted to separate the case, bolt the front half down to a mill table, indicate in the pin.....I guarantee you I COULD get 'er out or re-create the hole exactly by drilling and reaming....but that's a lot of work for little benefit.
freeze the pin with "Freeze Spray" and heat the case with a propane touch (not with MAP, Oxygen, etc). spray the "freeze Spray" on the pin repeatedly while heating the case.
this will expand the hole in the case, while contracting the mass of the pin.
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