Transfer Case Installation

Transfer Case





All vehicles
1. Install a new mounting gasket.





2. CAUTION: Secure the transfer case to the high-lift jack with a safety strap.

Raise the transfer case into position.





3. Install the six bolts retaining the transfer case to the extension housing.





Automatic transmission vehicles
4. Remove the jack stand from the extension housing.





5.Install the transmission mount.





6. NOTE: Typical is shown.

Position the crossmember and loosely install the two nuts.





F-Super Duty automatic transmission vehicles
7. Install the three LH crossmember bolts.





8. Install the RH crossmember bolts.








Excursion automatic transmission vehicles
9. Install the ten crossmember bolts.





10. Attach the wire harness to the crossmember.





All vehicles
11. Remove the high-lift jack.





Automatic transmission vehicles
12. Tighten the transmission mount-to-crossmember nuts.





All electric shift transfer cases
13. Connect the vent hose.








14. Connect the two gear motor encoder assembly electrical connectors.





All manual shift transfer cases
15. Connect the 3-position mode switch harness connector.
16. Connect the manual shift linkage.





All vehicles

17. CAUTION: Align the index-marks when installing the driveshaft.

Connect the front driveshaft to the transfer case and install the four new bolts.
18. Install the rear driveshaft.





19. If equipped, install the skid plate and the four bolts.
20. If drained, fill the transfer case.