Removal and Replacement
Transfer Case Removal and Installation
Removal
Caution: The three way catalytic converter ( TWC )( 5E212 ) is located beside the transfer case ( 7A195 ). Be careful when working around the three way catalytic converter because of the extremely high temperatures generated by the three way catalytic converter.
1. Raise the vehicle on a hoist and position suitable safety stands under vehicle.
2. If so equipped, remove the skid plate from the frame (5005).
3. Remove the damper from the transfer case, if so equipped.
Note: Drain transfer case only if transfer case disassembly is required.
4. To drain transfer case oil, place a drain pan under transfer case, remove the drain plug and drain fluid from the transfer case.
5. Disconnect the wire connector of the four-wheel drive indicator switch at the transfer case.
6. Disconnect the front driveshaft (4602) from the case yoke (7B214) and wire the driveshaft out of the way.
7. Disconnect the rear driveshaft from the case yoke and wire the driveshaft out of the way.
8. Disconnect the speedometer cable (17260) from the case (7005).
9. Disconnect the transfer case breather tube from the gearshift lever housing.
10. Remove the nut from the shift lever and disconnect the shift lever.
11. Remove the large bolt and the small bolt retaining the shifter to the extension housing (7A039). Remove the gearshift lever (7210) and gearshift lever socket bushing (7335).
12. Support the transfer case with a transmission jack, such as Rotunda 077-00019 or equivalent.
13. Remove the five bolts retaining the transfer case to the transmission (7003) extension housing.
14. Slide the transfer case rearward off the transmission output shaft and lower the transfer case from the vehicle. Remove the gasket from between the transfer case and transmission extension housing. Clean gasket mating surfaces prior to transfer case installation.
Installation
1. Place a new gasket on the front mounting face of the transfer case. If necessary, use a small daub of premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B to hold the gasket down.
2. Raise the transfer case with the transmission output shaft align with the input shaft (7017). Slide the transfer case forward onto the transmission output shaft and onto the dowel pin. Install the five bolts (7A443) retaining the transfer case to the transmission extension housing. Tighten bolts to 34 - 48 Nm ( 25 - 35 lb ft ) in the sequence shown.
3. Remove the transmission jack from the transfer case.
4. Install and adjust the shifter.
Note: the upper end of the transfer case breather tube should be 19 mm (3/4 inch) above the notch in the shifter.
5. Install the vent assembly so the white marking on the transfer case breather tube is in position in the notch in the shifter.
6. Connect the speedometer cable to the case. Tighten the screws to 2 - 3 Nm ( 20 - 25 lb in ).
7. Connect the rear driveshaft to the case yoke. Tighten the bolts to 83 - 118 Nm ( 61 - 87 lb ft ).
8. Connect the front driveshaft to the case yoke. Tighten the bolts to 16 - 22 Nm ( 12 - 16 lb ft ).
9. Connect the top gear indicator switch wire connector at the transfer case.
10. Install the drain plug and tighten to 19 - 30 Nm ( 14 - 22 lb ft ). Remove the fill plug and install Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or DDX or equivalent MERCON fluid to the bottom of the fill hole. Install fill plug and tighten to 20 - 27 Nm ( 14 - 22 lb ft ).
11. Install the damper to the transfer case, if so equipped. Using new damper bolts or previously removed bolts coated with Threadlock and Sealer E0AZ-19554-AA or equivalent meeting Ford specification WSK-M2G315-A5 Type II, tighten the bolts to 35 - 48 Nm ( 26 - 35 lb ft ).
12. Install the skid plate to frame (if equipped). Tighten nuts and bolts to 20 - 27 Nm ( 15 - 20 lb ft ).
13. Remove safety stands and lower vehicle from the hoist.