tried it today and I can't even remove the 4 bolts that holds the driveshaft from the transfer case output shaft flange. I guess they have loctite on them that even my 600 lb/ft impact can't budge loose the bolts.
Not comfortable on using heat/flame since it's very close to the gas tank.
Your impact MAY claim 600 lb-ft, but it certainly is not delivering anywhere near that. The bolts used on that flange will shear off way before such torque were applied. Mine were also difficult, but I broke them loose using a long pipe for leverage on a breaker bar. You may break a socket in this process. If room allows, use 1/2-inch drive socket, less likely to crack than 3/8.
Depending on year/model, your front driveshaft may have the round, can-type C-V joint at the transfer case end. If so, it requires stout sockets also, as they are loc-tited at the factory. I replaced those 6 screws with Allen-head socket cap screws, believe they are 8mm in size.
Removal of the transfer case after driveshafts out of the way is pretty straightforward. Bolts at front attach it to a short "extension" housing adaptor on the transmission. Trans. output shaft spline enters a female spline on the transfer case input shaft, whole thing slides right off. Unlike old days, where T.C. supported engine/trans. weight, these do not have any engine-type mount.
If you feel the need, PM me your name & mailing address and I will copy my Ford Shop Manual and mail it to you. I have this info. for 2nd. & 3rd. generation Explorers. Ask, if you have other questions, I do not have ALL the answers, but try my best.......imp
EDIT: I used no heat on any of the screws involved. I am limited to dial-up internet, VERY slow, so cannot send you Shop Manual pages by 'net. Sorry.
