Do you have to remove the torsion bars to get the transfer case out of a '97 Expy? Or, can it be shimmied out of there?

 

Quote:

Originally Posted by Rob_C

Do you have to remove the torsion bars to get the transfer case out of a '97 Expy? Or, can it be shimmied out of there?

it must be removed
<TABLE width="95%"><TBODY><TR><TD>Section 308-07B: Transfer Case
</TD><TD align=right>1997 Expedition Workshop Manual
</TD></TR></TBODY></TABLE>
REMOVAL
<HR>Transfer Case

****** name=tps_proctitle content="Transfer Case">

1. [IMG]file:///C:/TSO/tsocache/MEL-PC_5172/SVJ~us~en~file=ani_caut.gif~gen~ref.gif[/IMG] WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE, THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
   Raise and support the vehicle. Refer to Section 100-02 .

1. NOTE: Drain the transfer case (7A195) if disassembly is required.
   Drain the transfer case.
   • Remove the drain plug.

1. NOTE: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so they may be installed in their original positions.
   Remove the rear driveshaft.
   1. Remove the four bolts.
   1. Remove the rear driveshaft.

1. Remove the front driveshaft shield.
   1. Remove the two front driveshaft shield nuts.
   1. Remove the front driveshaft shield.

1. Disconnect the front driveshaft.
   1. Remove the four front driveshaft flange bolts.
   1. Disconnect the front driveshaft.

1. Remove the torsion bars and rear torsion bar support; refer to Section 204-01B .

1. Remove the transfer case skid plate.
   1. Remove the four transfer case skid plate bolts (two each side).
   1. Remove the transfer case skid plate.

1. Disconnect the vehicle speed sensor (VSS) electrical connector.

1. Disconnect the electric shift motor electrical connector.

1. Support the transfer case.
   • Use Hi-Lift Jack.
   • Secure the transfer case to jack with safety strap.

1. Remove the six transfer case to transmission bolts (three each side).

1. Lower the transfer case.

 

OK, I kinda thought so. Hey I tried to go to the Section 204-01B link but it's not working for some reason. Can you put that section on here?

 

There's a lot more to it than this section. Hope this helps.

<TABLE width="95%"><TBODY><TR><TD>Section 204-01B: Front Suspension, 4x4
</TD><TD align=right>1997 Expedition Workshop Manual
</TD></TR></TBODY></TABLE>
REMOVAL AND INSTALLATION
<HR>Torsion Bar

****** name=tps_proctitle content="Torsion Bar">
<TABLE border=1 cellSpacing=0 cellPadding=3 width="50%"><CAPTION>Special Service Tool(s) </CAPTION><TBODY><TR vAlign=top><TD>[IMG]file:///C:/TSO/tsocache/MEL-PC_5172/SVJ~us~en~file=ST1355A.gif~gen~ref.gif[/IMG]</TD><TD>Torsion Bar Tool
T95T-5310-A </TD></TR><TR vAlign=top><TD>[IMG]file:///C:/TSO/tsocache/MEL-PC_5172/SVJ~us~en~file=ST1386A.gif~gen~ref.gif[/IMG]</TD><TD>Torsion Bar Tool Adapters
T96T-5310-A </TD></TR></TBODY></TABLE>
Removal

1. [IMG]file:///C:/TSO/tsocache/MEL-PC_5172/SVJ~us~en~file=ani_caut.gif~gen~ref.gif[/IMG] WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
   Raise and support the vehicle; refer to Section 100-02 .

1. Make preliminary adjustment references.
   1. Make an alignment mark on the torsion bar and the torsion bar crossmember support.
   1. Measure and record the length.

1. Relieve the torsion bar tension.
   1. Remove the torsion bar adjuster bolt.
   1. Install Torsion Bar Tool with Torsion Bar Tool Adapters in the B slots on Torsion Bar Tool.
   1. Tighten Torsion Bar Tool until the torsion bar adjuster lifts off of the adjuster nut.
   1. Remove the torsion bar adjuster nut.
   1. Remove Torsion Bar Tool.
   1. Remove the torsion bar adjuster.
   • Repeat for the other side.

1. Remove the torsion bars.
   1. Remove the torsion bar crossmember support bolts and nuts.
   1. Remove the torsion bar crossmember support.
   1. Remove the torsion bars.

Installation

1. Install the torsion bar.
   1. Position the torsion bars.
   1. Position the torsion bar crossmember support.
   1. Install the torsion bar crossmember support bolts and nuts.

1. Load the torsion bar.
   1. Install the torsion bar adjuster.
   1. Install Torsion Bar Tool with Torsion Bar Tool Adapters in the B slots on the torsion bar tool.
   1. Tighten Torsion Bar Tool to load the torsion bar.
   1. Install the torsion bar adjuster nut.
   1. Install the torsion bar adjuster bolt.
   1. Remove Torsion Bar Tool.
   • Turn the torsion bar adjuster until the reference marks align.
   • Repeat for the other side.

1. Adjust the ride height; refer to procedure in this section.