'99 Expy, 153K miles, AWD.

Need to remove the transfer case as it is stuck in 4WD.

The issue is getting the torsion bar adjuster nut off. The instructions say to use a Ford specialty tool, 204-185 and 204-203 to push the torsion bar adjusting bracket up and out of the way to remove the nut and blah, blah, blah. No local auto parts store has these tools to "loan" and the best price I can find on it is $149.

Is there a shadetree work around? I really need to get this done....the old lady is up my a$$ about getting her rig back on the road.

 

Some people have done the job using a C-clamp instead of the specialty tool. I imaging the C-clamp has to be just the right size for it to work.

 

I tried two C clamps: Wilton 9", the pitch of the screw is too course. Harbor Freight 9", screw has a tighter pitch to it, welded a nut to the bottom of the screw rather than bending the crap outa the "T-handle" thing.

Neither worked. Of the two, the Wilton worked better, to a point. I'm thinking that I'll weld a nut to the bottom of the screw on it too and give it another shot.

Took the flat 'foot' thing off the screw and inserted the ball end of the screw into the socket of the torsion adjuster.

 

I used the adjusting bolt to run the torsion adjuster up, held it in place with a clamp, removed the nut, slowly released the adjuster with the clamp.

Don't know how I'll put it all back together, but the taking it apart seems to be solved for now.

 

Although I haven't done it myself, I'm told that if you pop the lower ball joint from the steering knuckles and disconnect the shocks, that you can then swing the lower control arms down to further relieve pressure off the torsion bars. If you're doing one side only, then you would have to also disconnect the sway bar link on that side.