How do you split the cases.

Numbers are not considered lower case. Turn your CAPS LOCK on and type your postcode. If there is still a problem, contact customer support.

Check again for a bolt on the inside surfaces of the cases. All bolts are NOT on the edges!!!

is the lever moving on transfer case or is it a inturnal silanoid?
fords are easy fixers.. if that moving then reach in to the front u-joint see they are locked if not fix that hub,, if good the shift fork in the case is broke
you can split the case with it on the truck $25 for a fork last time i fix one
just undo shaft, speedo, c-ring cone cover, center case bolts torq size?

you should see a split on the top of the remote, use a small flat head screw driver (like a jewelers flat head) and carefully insert it in the split and attempt to pry the top (button) side plate away from the case. There are 3 retention clips on each side of the front and back plates that hold them to the gray center plastic.
It's easiest to start from that crack and carefully continue prying along the parameter. Remember, the clips are attached to the black plates, so attempt to pry the gray piece away as you pull the black plate up and away.

Sounds like you either have a vaccum leak or your 4 wheel drive actuator is not working to engage the front differential.On my 98 ram there is a black and red plastic lines that are used for the vaccum lines. They are underneath and go from the transfer case to the front axle, check to see if one or both might be cracked or broke completely.If the lines are good then it could be your actuator on the front axle. A new one is about $93 at advance auto parts and not very hard to replace

No tricks, just make sure its picking up voltage at the same point your compressor is. Make sure the fan is actually a functioning motor.

This works for my DCP-7020, so it may work on the 7040.

If your drum is still good - take it out and put it back in - the trick is to LEAVE THE FRONT DOOR OPEN after you put it back in. With the door still OPEN push the "options" button and you will be prompted for "New Drum?" and then push the "Up" button for 'Yes' and "Accepted" will appear on the lcd screen - and then the drum counter will be reset.

no tricks it is very difficult and very easy to break the cases just take your time with it and work them apart

Check your fuel cap. You may have to buy a new one in some cases because the seal on the old one has gone bad. Before you buy a new one though.... Tighten the old one and try to erase the code is it doesn't go out by itself.

New bar and chain should do the trick. ONCE IT GETS A LITTLE DULL T BUILDS UP HEAT AND STRETCHES. Use a good quality case hardened chain they last longer and are well worth the extra money.