Mercury F77Z-7A039-CA Transmission Extension Housing

Apexing of a transfer case is another complex task for the would-be mechanic, just like overhauling of a transmission because it involves dismantling of many small parts involving huge number of clearances all of which have to be measured very closely for the use of select-fit spacers, snap-rings etc. Procedures for the removal and installation of the transfer case are well within the capabilities of a competent do-it-yourselfer; however, the actual process of the overhaul generally should be left to a specialist repair shop In many cases you may be able to obtain rebuilt transfer cases through dealer parts departments or auto parts stores, and this is often the reason why the cost for an overhaul job will be higher than that of the rebuilt unit. While a relatively new car mechanic can attempt a rebuild with relative ease if he has the right special tools as well as ensure he takes his time and do not skip any steps. The special equipment necessary for the job includes internal and external snap ring pliers, bearing puller, slide hammer, set of pin punches, dial indicator, hydraulic press, if available and a large heavy duty working bench and vice. Notes should be taken of the exact location or position of each of the parts during the disassembly process and the knowledge of the area of the transfer case that is faulty makes the analysis and isolation of parts easier.

On models so equipped, remove the bolts securing the skid plate to the frame and remove it.

Disconnect the vent hose from the shift lever bracket (manual shift) or mounting bracket (electronic shift) (Disconnect the vent hose from its bracket (electronic shift models)).

Remove the nut from the shift lever and remove the shift lever.