Installation

1. Position the transfer case onto jack.
- Use Hi-Lift Jack.
- Secure the transfer case.

2. Position the transfer case.





3. Install the six transfer case to transmission bolts (three each side).





4. Connect the vehicle speed sensor (VSS) electrical connector.





5. Connect the electric shift motor electrical connector.





6. Install the transfer case skid plate.
(1) Position the transfer case skid plate.
(2) Install the four transfer case skid plate bolts (two each side).

7. Install the torsion bars and rear torsion bar support.





8. Connect the front driveshaft.
(1) Position the front driveshaft.
(2) Install the four bolts.

NOTE: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so they may be installed in their original positions.





9. Install the front driveshaft shield.
(1) Position the front driveshaft shield.
(2) Install the front driveshaft shield nuts.





10. Install the rear driveshaft.
(1) Position the rear driveshaft.
(2) Install the four rear driveshaft flange bolts.





11. If drained, fill the transfer case.
- Use Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or DDX or equivalent MERCON fluid.

12. Lower the vehicle.

NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch.