Transfer Case Installation
Transfer Case1. NOTE: Install the transfer case with a new gasket.
NOTE: Tighten the bolts that retain the transfer case to the extension housing in a clockwise direction beginning with the upper LH bolt.
NOTE: Install the front driveshaft with new bolts and washers and the rear driveshaft with new bolts. If new bolts are not available, coat the threads of the original bolts with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5.
NOTE: When installing the front driveshaft, always connect it to the axle first and then connect it to the transfer case.
NOTE: Align the index marks when installing the front and rear driveshafts.
To install, reverse the removal procedure.
2. Check and, if necessary, fill the transfer case with the specified type and quantity of fluid.
3. Adjust the shift linkage.
1 Raise the shift boot to expose the top surface of the cam plate.
2 Loosen the bolts approximately one turn. Move the transfer case shift lever to the 4L position (lever in rearmost position on the cam plate).
3 Rotate the cam plate clockwise around the center bolt until the bottom chamfered corner of the neutral lug just contacts the forward right edge of the shift lever.
4 Hold the cam plate in this position and tighten the bolt first to 108 Nm (80 ft. lbs.).
5 Tighten the second bolt to 49 Nm (36 ft. lbs.).
^ Move the transfer case in-cab shift lever to all shift positions to check for positive engagement. There should be clearance between the shift lever and cam plate in the 2H front, 4H rear. Clearance should not exceed 3.30 mm (0.13 inch), and 4L shift positions.