> The transfer case has a high percentage of magnesium and is very prone to cracking.
I did not know that, my 1995 EAWD (e=extended not electric) made it to 180,000+ miles with no problems, including off road and through the fields. I worked at a MASS Ford dealer and never saw a broken transfer case. Though there were one or two people that needed the Dana 28 replaced because they never changed the fluid (or checked it).
Running 235s is impressive, I have bought these tires for my F-150 I am restoring, though I use to buy the 235s from treadwright instead with the kwedge grip, but, I guess they have given up on 15" tire support.
Great in town and country mud and snow. Provides excellent traction in all weather conditions. 4 or more ships free!
www.tirerecappers.com
> I’m swapping the transfer case
Just swapping in a manual transfer case from a B2 or Ranger? Always wanted to do that with mine, especially after I nuked a front hub/axle and learned the only way to disable the AWD so you can actually drive it is to remove the fuse under the driver's seat.