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Home >> Ford >> 2002 >> Taurus SES, 3.0 S >> Repair and Diagnosis >> External Pages >> Different car >> Section 368 (Transfer Case Removal & Installation - Excursion & F250-F550 Super Duty) >> In-Vehicle Repair >> Transfer Case Shift Lever >> Installation

Transfer Case Shift Lever: Installation

WARNING: This page is about a different car, the 2003 Ford Pickup, 2003 Ford F550 Super Duty, 2003 Ford F450 Super Duty, 2003 Ford Excursion, and 2003 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: DO NOT  tighten the bolt that attaches the transfer case control lever assembly to the transmission case at this time.
    Fig 1: Identifying Threaded Holes
    G01554117Courtesy of FORD MOTOR CO.
  1. Align the new transfer case control lever assembly pivot bolt over the correct mounting hole in the transmission case and start the bolt into the threaded hole by hand.
    1. For vehicles with a gasoline engine and manual transmission, or a diesel engine and manual or automatic transmission, install the new bolt in the forward (LH) threaded hole in the transmission case.
    2. For vehicles with a gasoline engine and automatic transmission, install the new bolt in the rearward (RH) threaded hole in the transmission case.
  2. Position the second bolt in the unused threaded hole in the transmission case.
    • For vehicles with a gasoline engine and manual transmission, or a diesel engine and manual or automatic transmission, position the pin in the rearward (RH) threaded hole in the transmission case.
    • For vehicles with a gasoline engine and automatic transmission, position the pin in the forward (LH) threaded hole in the transmission case.
    3. CAUTION: Verify that the control rod is still attached correctly to the transfer case.
    CAUTION: Verify that the transfer case is still in 4H.
    Fig 2: Connecting Control Rod To Lower Shifter Arm
    G01554118Courtesy of FORD MOTOR CO.
  3. Connect the control rod to the lower shifter arm.
    4. CAUTION: Make sure the transfer case is in 4H. Hold the control lever against the 4H detent while tightening the bolt. This will ensure correct transfer case gear engagement during transfer case operation.
    Fig 3: Holding Control Lever Against 4H Detent
    G01554119Courtesy of FORD MOTOR CO.
  4. Hold the control lever against the 4H detent while tightening the bolt.
  5. Lower the vehicle.
  6. Position the shift lever with the bezel and boot assembly and install the bolt.
    Fig 4: Installing Shift Lever With Bezel & Boot Assembly
    G01554120Courtesy of FORD MOTOR CO.
  7. Position the bezel and boot assembly and install the screws.
    Fig 5: Installing Bezel & Boot Assembly
    G01554121Courtesy of FORD MOTOR CO.
  8. Verify the shift sequence from 2H to 4L to 2H.
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