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.

Fig 1: Material Specification

Courtesy of FORD MOTOR CO.

NOTE: Shift the transfer case to 2W HI.

All Vehicles
Raise and support the vehicle.
Remove the four bolts and the skid plate, if equipped.

Fig 2: Remove Skid Plate
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NOTE: Index-mark the driveshaft to maintain driveline balance.

Remove the rear driveshaft. See REMOVAL & INSTALLATION .
Index-mark the front driveshaft to the transfer case flange.

Fig 3: Index-Marking Front Driveshaft To Transfer Case Flange
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NOTE: Support the front driveshaft with wire or a strap.

Fig 4: Removing Front Driveshaft

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Remove and discard the four bolts and position the front driveshaft aside.

Manual Shift Transfer Case Models

Remove the manual shift linkage, if equipped.

Fig 5: Removing Manual Shift Linkage
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Disconnect the switch electrical connector. Position the wire harness aside.

Fig 6: Disconnecting Switch Electrical Connector (Manual Shift)
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Fig 7: Disconnecting Switch Electrical Connector (Electric Shift)
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Electric Shift Transfer Case Models

Disconnect the gear motor encoder assembly electrical connector and the gear motor electrical connector. Position the wire harness aside.

Fig 8: Disconnecting Gear Motor Encoder Assembly Electrical Connector
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Disconnect the transfer case vent hose.

Fig 9: Disconnecting Transfer Case Vent Hose
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All Transfer Cases

If disassembly is necessary, drain the fluid into a suitable container.
- Install the plug when finished.
Fig 10: Identifying Drain Plug
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Position a suitable high-lift jack under the transfer case and secure it with safety straps.

Fig 11: Securing High-Lift Jack Under Transfer Case
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Excursion Vehicles

Detach the wire harness from the crossmember.

Fig 12: Detaching Wire Harness From Crossmember
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Remove the ten crossmember-to-frame bolts.

Fig 13: Identifying Crossmember-To-Frame Bolts (Excursion)
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F-Super Duty Automatic Transmission Vehicles

Remove the four RH crossmember bolts.

Fig 14: Identifying RH Crossmember Bolts (F-Super Duty)
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Remove the three LH crossmember bolts.

Fig 15: Identifying LH Crossmember Bolts (F-Super Duty)
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NOTE: Typical is shown.

Fig 16: Removing Crossmember

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All Vehicles Equipped With Automatic Transmissions
Remove the transmission mount nuts and the crossmember.
Remove the transmission mount.

Fig 17: Removing Transmission Mount
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Position a suitable jack stand under the extension housing.

Fig 18: Positioning Jack Stand Under Extension Housing
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All Vehicles

Remove the six transfer case-to-transmission bolts.

Fig 19: Removing Transfer Case-To-Transmission Bolts
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Separate the transfer case from the extension housing. Pull the transfer case rearward, then lower the transfer case from the vehicle.

CAUTION: Carefully clean the gasket surfaces. Nicks and gouges cause fluid leaks.

Fig 20: Identifying Mating Surface

Courtesy of FORD MOTOR CO.

Remove the transfer case-to-transmission gasket. Clean the mating surfaces, using metal surface cleaner.