Transfer Case Swap

10/05/14 - 12/13/14
February 2015: I swapped back to the factory transfer case. The refurbished unit below would pop out of high gear. Buyer beware. A rebuild will be necessary to use the new transfer case. I will leave this page up for reference on swapping a transfer case into a Deuce.

The factory transfer case on my deuce was looking worn out. I was the winning bidder on a refurbished transfer case from the Fort Polk location of Government Liquidation. I drove my Ford Expedition to the base and brought it back home.

Removal of the transfer case is pretty similar to taking out the factory deuce 5-speed transmission. Take out the floor board tunnel plates, use a crane + comealong on the top, and lower down to a furniture dolly. I have no idea how much the transfer case weighs, but it's somewhere between a crushed skull and a hernia. It's definitely a two person job at best, but I take the solo route most times because I don't want anybody else to get hurt working on this beast.

Before the new transfer case was installed I got the wild hair of replacing the pneumatic piston that actuates power to the front axle with something else. A few days of searching led me to the conclusion that a properly maintained pneumatic piston will do the job just fine. Just as a test I hooked up my shop compressor and regulator directly to the pneumatic piston assembly. The piston would not fully engage power to the front axle until the air pressure reached 30 psi. Just food for thought. The Holset QE296B compressor that I'm running on the Cummins 12 valve engine (6BT) cuts in at 105 psi and cuts out at 125 psi.

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