Removal (Explorer & Ranger)

WARNING: This page is about a different car, the 1996 Ford Ranger, 1996 Ford Pickup, 1996 Ford F-Super Duty, 1996 Ford Explorer, and 1996 Ford Bronco. However, it is still accessible from the selected car via links, so may be relevant.

Disconnect negative battery cable. Raise and support vehicle. Remove skid plate (if equipped). Remove vibration damper from transfer case (if equipped). If disassembling transfer case, drain fluid from transfer case. Install plug.
On manual shift transfer cases, disconnect 4WD indicator switch at transfer case. On electronic shift transfer cases, remove wire connector from feed wire harness at rear of transfer case.
On all models, mark and disconnect front and rear drive shafts from transfer case output shaft yokes. Wire drive-shafts aside. Remove vehicle speed sensor connector, nut and sensor. Disconnect vent hose from shift control selector lever and housing.
On manual shift transfer cases, remove shift lever retaining nut and lever. Remove both large and small bolt retaining shifter to extension housing. Remove shift control selector lever assembly and bushing.
On all models, support transfer case with a jack. Remove transmission exhaust heat shield and wiring harness. Remove bolts attaching transfer case to extension housing. Slide transfer case off transmission output shaft. Lower transfer case from vehicle. Remove gasket from transfer case and transmission extension housing.