Transfer Case

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

MATERIAL

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. For additional information, refer to JACKING AND LIFTING .
Remove the four bolts and the skid plate, if equipped.

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

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

Remove the rear driveshaft. For additional information, refer to DRIVESHAFT .
Index-mark the front driveshaft to the transfer case flange.

Fig 2: Identifying Index-Mark On Driveshaft And Transfer Case Flange
Courtesy of FORD MOTOR CO.

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

Fig 3: Locating Rear Driveshaft Bolts And Alignment Marks

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 (Manual Shift Transfer Case)

Courtesy of FORD MOTOR CO.

Electric shift transfer case

Fig 6: Disconnecting Gear Motor Encoder Assembly Electrical Connectors

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: Locating Transmission Insulator-To-Crossmember Support Nuts
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: Identifying Loosening Torque Of 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: Removing Transfer Case-To-Transmission Gasket

Courtesy of FORD MOTOR CO.

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