Transfer Case Actuator: Service and Repair

Removal

WARNING: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning of the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations.

1. Raise and support the vehicle.





2. Disconnect the electrical connector.





3. Remove the coil wire from the electrical connector.
1 Remove the connector interlock.
2 Remove the coil wire pin.
- Use the proper electrical connector pin remover.





4. CAUTION: Note each sensor wire pin location for correct installation.

Remove the front and rear output shaft speed sensor wire pins from the electrical connector.
- Use the proper electrical connector pin remover.





5. Remove the transfer case shift motor.
1 Remove the four bolts.
- Remove the transfer case shift motor.

Installation





1. NOTE: Make sure the motor mounting surfaces are clean.

Apply a 3 mm (1/8 inch) bead of sealant to the motor mounting surface on the case.
- Use Black Non-Acid Cure Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ES L-M4G273-A.





2. To install, reverse the removal procedure.