Transfer Case

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

All vehicles

Install a new mounting gasket.

Fig 1: Installing Mounting Gasket
Courtesy of FORD MOTOR CO.

CAUTION: Secure the transfer case to the high-lift jack with a safety strap.

Fig 2: Raising Transfer Case Into Position

Courtesy of FORD MOTOR CO.

Raise the transfer case into position.
Install the six bolts retaining the transfer case to the extension housing.

Fig 3: Installing Bolts Retaining Transfer Case To Extension Housing
Courtesy of FORD MOTOR CO.

Automatic transmission vehicles
Remove the jack stand from the extension housing.

Fig 4: Removing Jack Stand From Extension Housing
Courtesy of FORD MOTOR CO.
Install the transmission mount.

Fig 5: Installing Transmission Mount
Courtesy of FORD MOTOR CO.

NOTE: Typical is shown.

Fig 6: Installing Nuts

Courtesy of FORD MOTOR CO.

Position the crossmember and loosely install the two nuts.
Install the three LH crossmember bolts.

Fig 7: Installing LH Crossmember Bolts
Courtesy of FORD MOTOR CO.
Install the RH crossmember bolts.

Fig 8: Installing RH Crossmember Bolts
Courtesy of FORD MOTOR CO.

All vehicles
Remove the high-lift jack.

Fig 9: Removing High-Lift Jack
Courtesy of FORD MOTOR CO.

Automatic transmission vehicles
Tighten the transmission mount-to-crossmember nuts.

Fig 10: Tightening Transmission Mount-To-Crossmember Nuts
Courtesy of FORD MOTOR CO.

All electric shift transfer cases
Connect the vent hose.

Fig 11: Connecting Vent Hose
Courtesy of FORD MOTOR CO.
Connect the two gear motor encoder assembly electrical connectors.

Fig 12: Connecting Gear Motor Encoder Assembly Electrical Connectors (1 Of 2)
Courtesy of FORD MOTOR CO.

Fig 13: Connecting Gear Motor Encoder Assembly Electrical Connectors (2 Of 2)
Courtesy of FORD MOTOR CO.

All manual shift transfer cases
Connect the 3-position mode switch harness connector.

Fig 14: Connecting 3-Position Mode Switch Harness Connector
Courtesy of FORD MOTOR CO.
Connect the manual shift linkage.
All vehicles

CAUTION: Align the index-marks when installing the driveshaft.

Fig 15: Connecting Front Driveshaft To Transfer Case

Courtesy of FORD MOTOR CO.

Connect the front driveshaft to the transfer case and install the four new bolts.
Install the rear driveshaft. Refer to DRIVESHAFT .
If equipped, install the skid plate and the four bolts.

Fig 16: Installing Skid Plate And Bolts
Courtesy of FORD MOTOR CO.
If drained, fill the transfer case. Refer to TRANSFER CASE DRAINING AND FILLING .