transfer case removal problem

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May 18, 2020 | 04:14 PM

37smitty

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transfer case removal problem

The transmission in my son's truck is shot (99 F250 super duty 6.0 swap) We pulled the transmission an transfer case as a unit. When we tried to remove the transfer case we broke every bolt. We used a lot of heat and it was still an epic fail. I have tried every trick I know and I can't get the bolts out or the transfer case to split from the transmission.. unless someone has a great idea my next attempt will be to start drilling or grinding the bolts out with an angle die grinder. only going as deep as needed to get it separated from the extension housing. At that point
I still have to get the bolts out of the transfer case. Does anybody know the bolt size for extension housing to transfer case ? If I ever get these out I want to have everything on hand to repair and put it back together.
Thanks Dave

May 19, 2020 | 10:01 PM

37smitty

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shameless bump.. I would even appreciate bad ideas at this point. I may have to sacrifice the extension housing to try to save the transfer case.

May 19, 2020 | 10:06 PM

WWR

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I've got nothing, read when you first posted. The bolt HEADS are snapping off and there's just corrosion where they pass through the t-case? 'Cause I mean otherwise if you're snapping heads the 'case would still slide back on the broken bolts (now effectively studs)?

Not doubting you, just trying to understand. Are you in the rust/salt belt?

May 20, 2020 | 07:01 PM

37smitty

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As strange as it seems that is the situation. It seems to have lived most of it's life in Mass. I have bolts/studs soaking in Ammonia now. That's a new one for me.

May 24, 2020 | 06:29 PM

37smitty

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Well I finally broke the transmission extension housing. After the 1st crack I just grabbed the air chisel and removed the extension housing in about 50 pieces. No damage to the transfer case. I welded nuts onto the broken bolts and they came out with very little effort. The bolts had become one with the extension housing.