Thanks for the information Carl. I think I will get a transfer case gasket just in case there is a problem removing them together.
I think you are right about the front Y-pipe connections being the flare type. The Ford repair manual does not say to throw the gasket away like they do for the rear Y-pipe connection.
Being in So Cal, I usually don't have a problem with frozen nuts. However, since the exhaust nuts get heat oxidation and they have been on there for over 100,000 miles they may be a problem. I plan to use a good penetrant and let it soak overnight then hit it again before removing. That usually takes care of it. I really don't want to waste time on replacing studs.
I was surprised to see in the repair manual that you should throw away the bolts and washers for the drive shafts. Then I saw later, if new fasteners are not available you can use a thread locking sealant on the old ones. Apparently, they prefer you to buy new bolts with locking seal already on it instead of using Locktite. A good source of profits.
2002 FX4 Bright Red Supercab 4.0 SOHC, manual 5-spd & Tcase, 33" BFG MTs, K&N air filter, Modified air box inlet, Gibson SS cat. back exhaust, Bama flash, Hidden Hitch round receiver, Rear helper air springs, Electric trailer brake controller, Line-X bed liner, WAAG bar with KC lights and Wildernest shell.