Transfer Case

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Material

MATERIAL SPECIFICATIONS

Item	Specification
Metal Surface Cleaner F4AZ-19A536-RA	WSE-M5B392-A

All vehicles

NOTE: Shift the transfer case to 2W HI.

Raise and support the vehicle. Refer to JACKING & LIFTING .
Remove the four bolts and the skid plate, if equipped.

Fig 1: Removing Bolts And Skid Plate
Courtesy of FORD MOTOR CO.

NOTE: Index-mark the driveshaft to maintain driveline balance.

Remove the rear driveshaft. Refer to DRIVESHAFT .
Index-mark the front driveshaft to the transfer case flange.

Fig 2: Identifying Index-Mark Position
Courtesy of FORD MOTOR CO.

NOTE: Support the front driveshaft with wire or a strap.

Fig 3: Removing Bolts

Courtesy of FORD MOTOR CO.

Remove and discard the four bolts and position the front driveshaft aside.
Manual shift transfer case
Remove the manual shift linkage, if equipped.

Fig 4: Removing Manual Shift Linkage
Courtesy of FORD MOTOR CO.
Disconnect the switch electrical connector. Position the wire harness aside.

Fig 5: Disconnecting Switch Electrical Connector
Courtesy of FORD MOTOR CO.

Electric shift transfer case

Fig 6: Identifying Electric Shift Transfer Case Components
Courtesy of FORD MOTOR CO.
Disconnect the gear motor encoder assembly electrical connector and the gear motor electrical connector. Position the wire harness aside.

Fig 7: Disconnecting Gear Motor Encoder Assembly Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the transfer case vent hose.

Fig 8: Disconnecting Transfer Case Vent Hose
Courtesy of FORD MOTOR CO.

All transfer cases
If disassembly is necessary, drain the fluid into a suitable container.
- Install the plug when finished.
  
  Fig 9: Installing Plug
  Courtesy of FORD MOTOR CO.
Position a suitable high-lift jack under the transfer case and secure it with safety straps.

Fig 10: Positioning High-Lift Jack Under Transfer Case
Courtesy of FORD MOTOR CO.

All vehicles equipped with automatic transmissions
Remove the four RH crossmember bolts.

Fig 11: Removing RH Crossmember Bolts
Courtesy of FORD MOTOR CO.
Remove the three LH crossmember bolts.

Fig 12: Removing LH Crossmember Bolts
Courtesy of FORD MOTOR CO.
Remove the nuts and the crossmember.

Fig 13: Removing Nuts And Crossmember
Courtesy of FORD MOTOR CO.
Remove the transmission mount.

Fig 14: Removing Transmission Mount
Courtesy of FORD MOTOR CO.
Position a suitable jack stand under the extension housing.

Fig 15: Positioning Jack Stand Under Extension Housing
Courtesy of FORD MOTOR CO.

All vehicles
Remove the six transfer case-to-transmission bolts.

Fig 16: Removing Transfer Case-To-Transmission Bolts
Courtesy of FORD MOTOR CO.
Separate the transfer case from the extension housing. Pull the transfer case rearward, then lower the transfer case from the vehicle.

CAUTION: Carefully clean the gasket surfaces. Nicks and gouges cause fluid leaks.

Fig 17: Cleaning Mating Surfaces, Using Metal Surface Cleaner

Courtesy of FORD MOTOR CO.

Remove the transfer case-to-transmission gasket. Clean the mating surfaces, using metal surface cleaner.