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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) >> Installation >> Transfer Case

Transfer Case

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.

  1. All Vehicles

    Install a new mounting gasket.
    Fig 1: Installing Mounting Gasket To Mating Surface
    G01554264Courtesy of FORD MOTOR CO.
    2. CAUTION: Secure the transfer case to the high-lift jack with a safety strap.
    Fig 2: Positioning Transfer Case For Installation
    G01554265Courtesy of FORD MOTOR CO.
  2. Raise the transfer case into position.
  3. Install the six bolts retaining the transfer case to the extension housing.
    Fig 3: Installing Transfer Case-To-Extension Housing Bolts
    G01554266Courtesy of FORD MOTOR CO.

  4. Automatic Transmission Vehicles

    Remove the jack stand from the extension housing.
    Fig 4: Removing Jack Stand
    G01554267Courtesy of FORD MOTOR CO.
  5. Install the transmission mount.
    Fig 5: Installing Transmission Mount
    G01554268Courtesy of FORD MOTOR CO.
    6. NOTE: Typical is shown.
    Fig 6: Installing Crossmember
    G01554269Courtesy of FORD MOTOR CO.
  6. Position the crossmember and loosely install the two nuts.

  7. F-Super Duty Automatic Transmission Vehicles

    Install the three LH crossmember bolts.
    Fig 7: Installing LH Crossmember Bolts
    G01554270Courtesy of FORD MOTOR CO.
  8. Install the RH crossmember bolts.
    Fig 8: Installing RH Crossmember Bolts
    G01554271Courtesy of FORD MOTOR CO.

  9. Excursion Automatic Transmission Vehicles

    Install the ten crossmember bolts.
    Fig 9: Installing Crossmember Bolts (Excursion - 1 Of 2)
    G01554272Courtesy of FORD MOTOR CO.
    Fig 10: Installing Crossmember Bolts (Excursion - 2 Of 2)
    G01554273Courtesy of FORD MOTOR CO.
  10. Attach the wire harness to the crossmember.
    Fig 11: Attaching Wire Harness To Crossmember
    G01554274Courtesy of FORD MOTOR CO.

  11. All vehicles

    Remove the high-lift jack.
    Fig 12: Removing High-Lift Jack
    G01554275Courtesy of FORD MOTOR CO.

  12. Automatic Transmission Vehicles

    Tighten the transmission mount-to-crossmember nuts.
    Fig 13: Tightening Transmission Mount-To-Crossmember Nuts
    G01554276Courtesy of FORD MOTOR CO.

  13. All Electric Shift Transfer Cases

    Connect the vent hose.
    Fig 14: Connecting Transfer Case Vent Hose
    G01554277Courtesy of FORD MOTOR CO.
  14. Connect the two gear motor encoder assembly electrical connectors.
    Fig 15: Connecting Two Gear Motor Encoder Assembly Electrical Connectors (1 Of 2)
    G01554278Courtesy of FORD MOTOR CO.
    Fig 16: Connecting Two Gear Motor Encoder Assembly Electrical Connectors (2 Of 2)
    G01554279Courtesy of FORD MOTOR CO.

  15. All Manual Shift Transfer Cases

    Connect the 3-position mode switch harness connector.
    Fig 17: Connecting Mode Switch Harness Connector
    G01554280Courtesy of FORD MOTOR CO.
  16. Connect the manual shift linkage.
    17. CAUTION: Align the index-marks when installing the driveshaft.
    Fig 18: Connecting Front Driveshaft To Transfer Case
    G01554281Courtesy of FORD MOTOR CO.

  17. All Vehicles
    Connect the front driveshaft to the transfer case and install the four new bolts.
  18. Install the rear driveshaft. See REMOVAL & INSTALLATION .
  19. If equipped, install the skid plate and the four bolts.
    Fig 19: Installing Skid Plate
    G01554282Courtesy of FORD MOTOR CO.
  20. If drained, fill the transfer case.
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