Removal and Replacement
Transfer Case Removal and Installation Procedure
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 extreme temperatures generated by the three way catalytic converter.
1. Raise the vehicle on a hoist and position suitable safety stands under vehicle.
2. Remove skid plate from frame (5005), if equipped.
3. Remove the damper from the transfer case, if equipped.
Note: Drain transfer case only if transfer case disassembly is required.
4. Place a drain pan under the transfer case. Remove the drain plug and drain the fluid from the transfer case.
Caution: Do not pull directly on the wires or pull outwardly on the locking tabs.
5. Remove the wire connector from the feed wire harness at the rear of the transfer case. First squeeze the locking tabs, then pull the connectors apart. Remove the connector for the transfer case shift motor from the mounting bracket.
Note: For detailed instructions on front and rear driveshaft (4602) refer to the removal and installation procedure.
6. Disconnect the front driveshaft from the case flange and wire the driveshaft out of the way.
7. Disconnect the rear driveshaft from the case flange and wire the driveshaft out of the way.
8. Disconnect the speedometer drive gear (17285) from the transfer case rear case (7005).
9. Disconnect the transfer case breather tube from the mounting bracket.
10. Support the transfer case with Rotunda Transmission Jack 077-00019 or equivalent.
11. Remove the five bolts retaining the transfer case to the transmission extension housing.
12. Slide the transfer case rearward off the transmission output shaft and lower the transfer case from the vehicle. Remove the extension housing gasket (7086) from the transfer case and transmission extension housing area. Clean gasket surfaces before transfer case is reinstalled.
Installation
1. Place a new extension housing gasket on the front mounting face of the transfer case. If necessary apply a small amount of grease to the extension housing gasket to hold it in place during assembly.
2. Raise the transfer case with the transmission jack so that the transmission output shaft aligns with the splined input shaft (7017). Slide the transfer case forward onto the transmission output shaft and onto the dowel pin. Install the five transfer case retaining bolts to the extension housing (7A039). Tighten the bolts to 34 - 48 Nm ( 23 - 35 lb ft ) in the sequence shown.
3. Remove the transmission jack from the the transfer case.
4. Install the transfer case breather tube so that the white marking on the transfer case breather tube aligns with the notch in the mounting bracket.
5. Connect the speedometer drive gear to the rear case. Tighten the bolt (7A443) to 2 - 3 Nm ( 20 - 25 lb in ).
6. Connect the rear driveshaft to the case flange. Tighten the bolts to 83 - 118 Nm ( 61 - 87 lb ft ).
7. Connect the front driveshaft to the case yoke (7B214). Tighten the bolts to 16 - 22 Nm ( 12 - 16 lb ft ).
8. Attach the connector for the transfer case shift motor to the mounting bracket.
9. Connect the wire connectors on the rear of the transfer case, making sure that the retaining tabs lock.
10. Check transfer case fluid level. If transfer case was drained during removal procedure, install the drain plug and tighten to 9 - 23 Nm ( 7 - 17 lb ft ). Remove the fill plug and install Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XR-2-QDX or DDX or equivalent MERCON fluid to the bottom of the fill hole. Install fill plugs and tighten to 9 - 23 Nm ( 7 - 17 lb ft ).
11. Install the damper (if equipped) using new nuts. Tighten the damper bolts to 34 - 48 Nm ( 25 - 35 lb ft ). If new nuts are not available, coat the threads of the used nuts with Ford Threadlock 262, E2FZ-19554-B or equivalent meeting Ford specification WSK-M2G315-A5 Type II and install. Tighten bolts to 34 - 48 Nm ( 25 - 35 lb ft ).
12. Install the skid plate, bolts and nuts to the frame and tighten to 20 - 27 Nm ( 15 - 20 lb ft ).
13. Remove safety stands and lower vehicle.