Transfer Case

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 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: Locating Mounting Gasket
Courtesy of FORD MOTOR CO.

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

Fig 2: Locating Transfer Case Into Position

Courtesy of FORD MOTOR CO.

Raise the transfer case into position.
Install the 6 transfer case-to-transmission bolts.
- Tighten to 50 Nm (37 lb-ft).
  
  Fig 3: Locating Transfer Case-To-Transmission Bolts
  Courtesy of FORD MOTOR CO.

Automatic transmission vehicles

Remove the jack stand from the extension housing.

Fig 4: Locating Jack Stand From Extension Housing
Courtesy of FORD MOTOR CO.
Install the transmission mount.
- Tighten to 95 Nm (70 lb-ft).
  
  Fig 5: Locating Transmission Mount
  Courtesy of FORD MOTOR CO.
Position the crossmember and loosely install the 2 transmission mount nuts.

Fig 6: Locating Transmission Mount Nuts
Courtesy of FORD MOTOR CO.
Install the 3 LH crossmember nuts.
- Tighten to 70 Nm (52 lb-ft).
  
  Fig 7: Locating LH Crossmember Nuts
  Courtesy of FORD MOTOR CO.
Install the RH crossmember nuts.
- Tighten to 70 Nm (52 lb-ft).
  
  Fig 8: Locating RH Crossmember Nuts
  Courtesy of FORD MOTOR CO.

All vehicles

Remove the high-lift jack.

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

Automatic transmission vehicles

Tighten the transmission mount-to-crossmember nuts.
- Tighten to 94 Nm (69 lb-ft).
  
  Fig 10: Locating Transmission Mount-To-Crossmember Nuts
  Courtesy of FORD MOTOR CO.

All electric shift transfer cases

Connect the vent hose.

Fig 11: Locating Vent Hose
Courtesy of FORD MOTOR CO.
Connect the 2 gear motor encoder assembly electrical connectors.

Fig 12: Locating Gear Motor Encoder Assembly
Courtesy of FORD MOTOR CO.

Fig 13: Locating Gear Motor Encoder Assembly Electrical Connectors
Courtesy of FORD MOTOR CO.

All manual shift transfer cases

Connect the 3-position mode switch harness connector.

Fig 14: Locating 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.

Connect the front driveshaft to the transfer case and install the 4 new front driveshaft flange bolts.
- Tighten to 111 Nm (82 lb-ft).
  
  Fig 15: Locating Front Driveshaft Flange Bolts
  Courtesy of FORD MOTOR CO.
Install the rear driveshaft. For additional information, refer to DRIVESHAFT .
If equipped, install the skid plate and the 4 bolts.
- Tighten to 24 Nm (18 lb-ft).
  
  Fig 16: Locating Skid Plate And Bolts
  Courtesy of FORD MOTOR CO.
If drained, fill the transfer case. For additional information, refer to TRANSFER CASE DRAINING AND FILLING .