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Old 07-04-2011, 01:39 PM   #1
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Location: Arcata, CA
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How to pull transfer case on Quigley w/47g tank

On a recent trip, the van developed the nasty habit of slipping out of gear while descending a steep grade in 4WD-Low. Got the oil changed after returning and had them look at the transfer case. The oil was burned. Had it drained and replaced.

I've since put 3K miles on it including about 40 miles of 4WD-High with no problems. The transfer case will eventually need to be replaced / rebuilt but since it only affects low range, it's not an emergency.

Here's my question -- When looking at it, my mechanic noticed that there are only a few inches between the case and the front of the 47g fuel tank and he's concerned that there isn't enough room to pull the case without moving / removing the fuel tank. Has anyone had any experience with this issue?? I really hate those jobs where it costs as much or more in labor to get to a part than it does to replace or fix it.

2002 E350 7.3 PSD
Quigley 4x4, EB50 floorplan
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Old 07-05-2011, 10:03 AM   #2
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Re: How to pull transfer case on Quigley w/47g tank

Don't know about that, but are you sure it's not just your linkage getting caught on the body or something and popping out? Since it's low range only, that's a real possibility, especially if it happens under load (twisting drivetrain)

and then
everything changed
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Old 07-05-2011, 09:10 PM   #3
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Location: AVL NC
Posts: 991
Re: How to pull transfer case on Quigley w/47g tank

What Jage said... Remove the shifter boot, put it in low & check clearance to the body.

If the t-case does need to come out, you'll have to drop the tank.
Chris Steuber
02 E350 7.3 (V4)
17 Focus RS, 90 SHO, 49 CJ2A, 89 LSC, 20 T250 AWD
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