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Transfer Case - Mechanical Shift

WARNING: This page is about a different car, the 2005 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
MATERIAL REFERENCE

Item Specification
MERCON® Automatic Transmission Fluid XT-2-QDX MERCON®
    NOTE: Index-mark the driveshaft to maintain initial driveshaft balance during installation.
  1. Remove the front driveshaft. For additional information, refer to DRIVESHAFT .
    2. NOTE: To maintain initial driveshaft balance, index-mark the rear driveshaft.
  2. Remove the rear driveshaft. For additional information, refer to DRIVESHAFT .
  3. Remove the skid plate, if equipped.
    • To install, tighten to 18 Nm (13 lb-ft).
    Fig 1: Removing Skid Plate
    G03965004Courtesy of FORD MOTOR CO.
  4. Drain the fluid if the transfer case is to be disassembled. For additional information, refer to TRANSFER CASE DRAINING AND FILLING .
  5. Disconnect the transfer case wire harness
    Fig 2: Disconnecting Transfer Case Wire Harness
    G03965005Courtesy of FORD MOTOR CO.
    6. NOTE: The transfer case shift linkage assembly is serviced as an assembly only. If any part is damaged or worn, install a new assembly.
    Fig 3: Disconnecting Shift Linkage From Shift Bracket Using 5/8-Inch Wrench
    G03965006Courtesy of FORD MOTOR CO.
  6. Using a 5/8-inch wrench, disconnect the shift linkage from the shift bracket.
  7. Disconnect the vent tube.
    Fig 4: Disconnecting Vent Tube
    G03934162Courtesy of FORD MOTOR CO.
    8. CAUTION: Secure the transfer case to the jack with a safety strap.
  8. Using a suitable jack, support the transfer case. Securely strap the transfer case to the jack.
  9. Remove the transfer case.
    • Remove the 6 transfer case-to-transmission bolts and separate the transfer case from the transmission.
      • To install, tighten to 47 Nm (35 lb-ft).
        • Tighten the transmission-to-transfer case bolts evenly in a star pattern.
    • Separate the transfer case from the transmission.
    Fig 5: Removing Transfer Case
    G03965008Courtesy of FORD MOTOR CO.
  10. Lower the transfer case from the vehicle.
    11. CAUTION: Carefully clean the gasket surfaces. Nicks and gouges cause fluid leaks.
  11. Remove the transfer case-to-transmission gasket and clean the mating surfaces.
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