O.T. F350 Clutch R R

Well, my son & I have started the job--small steps at a time--just got the truck jacked up on blocks and started the process. Like I said, small steps first--disconnected batteries, removing starter, began loosening drive shafts etc. My son noticed a chunk of aluminum broken out near the slave cylinder mount. This has me concerned since on the ZF, the bellhousing is one in the same with the transmission housing. I'm hoping I can patch this hole and drill crack stopper holes if I see any cracks. Lord knows we can't afford a new transmission housing and the labor involved in swapping the gears out etc. I had another question if anyone wants to weigh in:

Should I split the transfer case from the tranny before dropping the tranny or should I leave it connected? A buddy in our church (who does alot of mechanic work) is recommending I leave the two attached, but I heard other folks say to split them before lowering. As a reminder--this is a 2001 F350 SRW diesel 4x4 with the ZF 6 speed. We have a large (2000# cap.) tranny jack. Thanks in advance for any help. I work out of state and can only work the job for a few hours on Saturdays.

I have limited experience with 4x4 trannys and transfer cases, but I do know that the entire assembly removed as a unit can get a bit clumsy because it is very difficult to keep it balanced on the jack. The use of an actual transmission jack may make things easier though. Proceed with caution.

If you've got a good transmission jack,I'd leave them together.Just chain it to the jack,it ain't goin nowhere. I put a clutch in my 85 6.9 diesel two years ago and left them together with just an adapter plate on a floor jack.Did the job alone,no problem.

Ford service procedure calls for t.case removal from tranny.Does get a bit clumsy with t.case and tranny together.

Well when i replaced the clutch in my F350 4X4 with a 460 i left the transfer case attached to the trans, less nut and bolt twisten i just made sure that i had the transmission well chained down to the tranny jack . It did not take long to do the job as i am lucky to have all the neat toys to play with. done a lot of clutch jobs in the years i have been twisten wrenches .

I think I was the one that told you to split them. It can be done together but real cumbersome and more difficult to align. When you get it out and you see that it needs to be repaired most welding shops can weld alm. and not near as expensive as a new case.

The Ford service manual says to split them. I did it that way; Tcase comes off easily enough.

The less weight and bulk you have to deal with when the trans goes back in, the easier it will be to line up the splines on the input shaft with the clutch plate, and get the shaft into the pilot bearing. So I'd leave the Tcase off until the trans is back in place.

Get some threaded rod and make up some temporary alignment studs to screw into the bolt holes in the block. That makes it easier to line everything up. Once the tranny is in place, remove the studs and put the bolts back in.

I pulled my 89 F-150 trans and xfer case together (T-18 and BW 1356). Too hard to balance without proper brackets on floor jack, so took them apart when going back in. If you just have a standard floor jack with the round cup, you´re at risk of dropping them.