Transfer Case - 3.0L (4V): Installation

WARNING: This page is about a different car, the 2002 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: The linkshaft seal must be replaced whenever the halfshaft or transfer case is removed from the vehicle.

NOTE: If necessary, replace the RH differential fluid seal.

Fig 1: Installing Transfer Case

Courtesy of FORD MOTOR CO.

Install the transfer case.
- Install the bolts.
Install the bolt.

Fig 2: Installing Bolt
Courtesy of FORD MOTOR CO.
Install the bracket and the six bolts.

Fig 3: Installing Bracket
Courtesy of FORD MOTOR CO.
Install the RH exhaust manifold.
Connect the RH heated oxygen sensor (HO2S).

Fig 4: Connecting RH Heated Oxygen Sensor
Courtesy of FORD MOTOR CO.
Connect the EGR to exhaust manifold tube.

Fig 5: Connecting EGR To Exhaust Manifold Tube
Courtesy of FORD MOTOR CO.
Install the flex pipe and connect the hanger.

Fig 6: Installing Flex Pipe And Connect Hanger
Courtesy of FORD MOTOR CO.
Install the gasket and the nuts.

Fig 7: Installing Gasket And Nuts
Courtesy of FORD MOTOR CO.
Install the gasket and the nuts.

Fig 8: Identifying Tightening Torque Of Catalytic Converter Bolts
Courtesy of FORD MOTOR CO.
Connect the flexible Y-pipe to the exhaust manifold and install the two nuts.

Fig 9: Identifying Tightening Torque Of Y-Pipe To The Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.
Connect the RH catalyst monitor sensor.
Install the generator. Refer to GENERATOR .
Instal the crossmember brace and the four bolts.

Fig 10: Identifying Tightening Torque Of Crossmember Bolts
Courtesy of FORD MOTOR CO.
Check the transfer case fluid level. Refer to Transfer Case Draining and Filling .
Install the driveshaft. Refer to DRIVESHAFT .
Connect the battery ground cable.
Check the transaxle fluid level. Refer to CHECKING FLUID LEVEL .