I have a F-350 1996 7.5L Manual 1 Ton 4 Wheel Drive
The rear 4×4 case housing is cracked. what concerns or issues might I run into by leaving the transmission in the truck and remove the drive shafts and t-case only. By looking online the problems I see would be lining up the shifting forks in there proper locations. Money is tight and I rather do it myself than have a shop charge me more in labor than the actual part.
Removing the rear driveshaft is not recommended, only in an emergency to get home, not as a daily driver.
This is a ZF transmission it could be a ZF542 (casting number 1307) or a ZF547 (casting number 1317) 5 speed and all internal parts are loaded into the tail housing so the tail housing cannot be removed with the transmission in the vehicle as the front case needs to be removed to access the gear train and then the gear train can be removed from the extension housing.
We understand tight money, we only have new extension housing (no used housings available), your cost on the new housing is $299.00 and if you order it the factory technical rep walk you through changing it once you have the transmission out and on the bench
You will also need front and rear seal and 3 detent caps (minimum parts for this repair) are the only other parts you will need and that will be an additional $10 plus freight.
Once the transmission is out and on the bench you will need the following tools.
5mm Allen socket
6mm Allen socket
Screwdriver seal driver or something “socket” to install seals
If you would like to discuss this project in more detail give Scott a call 888-824-2012 he can help you.
You can see the other Ford ZF542 parts that we offer on our site.