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Installation (Aerostar)

  1. To install, reverse removal procedure. Use NEW gasket between transfer case and transmission extension housing. It may be necessary to use grease to hold gasket in place.
  2. Tighten transfer case bolts to specification in sequence. See Figure. See TORQUE SPECIFICATIONS .
  3. Apply light coat of grease to front drive shaft splines and inner edge of dust boot area on transfer case before installing. When installing drive shafts, align reference marks on drive shafts and flanges.
  4. Install and crimp NEW clamp to retain front drive shaft dust boot. Tighten drain plug to specification.
  5. Fill transfer case to bottom of filler plug hole with Motorcraft Mercon ATF (XT-2-QDX). Install filler plug, and tighten to specification. To install remaining components, reverse removal procedure.
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