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Transfer Case Draining and Filling

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
MATERIAL SPECIFICATION

Item Specification
MERCON® Automatic Transmission Fluid XT-2-QDX MERCON®
    CAUTION: Transfer case failure can result if the correct fill procedures are not followed.
  1. Remove the drain plug and drain the fluid.
  2. Clean and install the drain plug.
    • To install, tighten to 15 Nm (11 lb-ft).
  3. CAUTION: Incorrect fluid fill can result in transfer case failure.
    NOTE: The fluid level should be just below the fill plug.
    NOTE: Clean the area around the fill plug.
  4. Remove the fill plug and fill the transfer case.
    • The fluid must be just below the fill plug hole. Because the fluid can be reached with a finger does not mean the fluid is at the correct level. Make sure the fluid is level with the filler opening for the correct fluid level.
      Fig 1: Identifying Transfer Case Oil Level
      G03949489Courtesy of FORD MOTOR CO.
  5. Clean and install the fill plug.
    • To install, tighten to 15 Nm (11 lb-ft).