All vehicles

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Shift the transfer case to 2H.

With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
Remove the 4 bolts and the skid plate, if equipped.

Fig 1: Locating 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 article.
Index-mark the front driveshaft to the transfer case flange.

Fig 2: Index-Marking Front Driveshaft To Transfer Case Flange
Courtesy of FORD MOTOR CO.

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

Fig 3: Identifying Front Driveshaft Bolts

Courtesy of FORD MOTOR CO.

Remove and discard the 4 bolts and position the front driveshaft aside.

Remove the 6 transfer case-to-transmission bolts.

Fig 1: Locating 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 2: Identifying 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.