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Home >> Ford >> 2006 >> Focus ZX5 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 31 (Transfer Case -- F250-F550 Super Duty) >> Installation >> Transfer Case

Transfer Case

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

  1. Install a new mounting gasket.
    Fig 1: Installing Mounting Gasket
    G03909825Courtesy of FORD MOTOR CO.
    2. CAUTION: Secure the transfer case to the high-lift jack with a safety strap.
    Fig 2: Raising Transfer Case Into Position
    G03909818Courtesy 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: Identifying Tightening Torque Of Transfer Case To Extension Housing Retaining Bolts
    G03909824Courtesy of FORD MOTOR CO.

    4. Automatic transmission vehicles 

  4. Remove the jack stand from the extension housing.
    Fig 4: Removing Jack Stand From Extension Housing
    G03908783Courtesy of FORD MOTOR CO.
  5. Install the transmission mount.
    Fig 5: Identifying Tightening Torque Of Transmission Mount
    G03908784Courtesy of FORD MOTOR CO.
    6. NOTE: Typical is shown.
    Fig 6: Locating Transmission Insulator-To-Crossmember Support Nuts
    G03908285Courtesy of FORD MOTOR CO.
  6. Position the crossmember and loosely install the two nuts.
  7. Install the three LH crossmember bolts.
    Fig 7: Identifying Tightening Torque Of LH Crossmember Bolts
    G03923699Courtesy of FORD MOTOR CO.
  8. Install the RH crossmember bolts.
    Fig 8: Identifying Tightening Torque Of RH Crossmember Bolts
    G03923700Courtesy of FORD MOTOR CO.

    9. All vehicles 

  9. Remove the high-lift jack.
    Fig 9: Removing High-Lift Jack
    G03909818Courtesy of FORD MOTOR CO.

    10. Automatic transmission vehicles 

  10. Tighten the transmission mount-to-crossmember nuts.
    Fig 10: Identifying Tightening Torque Of Transmission Mount-To-Crossmember Nuts
    G03909000Courtesy of FORD MOTOR CO.

    11. All electric shift transfer cases 

  11. Connect the vent hose.
    Fig 11: Connecting Vent Hose
    G03909816Courtesy of FORD MOTOR CO.
  12. Connect the two gear motor encoder assembly electrical connectors.
    Fig 12: Connecting Gear Motor Encoder Assembly Electrical Connectors
    G03909814Courtesy of FORD MOTOR CO.
    Fig 13: Disconnecting Switch Electrical Connector
    G03909815Courtesy of FORD MOTOR CO.

    13. All manual shift transfer cases 

  13. Connect the 3-position mode switch harness connector.
    Fig 14: Connecting 3-Position Mode Switch Harness Connector
    G03909813Courtesy of FORD MOTOR CO.
  14. Connect the manual shift linkage.

    15. All vehicles 

    CAUTION: Align the index-marks when installing the driveshaft.
    Fig 15: Identifying Tightening Torque Of Front Driveshaft To Transfer Case Bolts
    G03909841Courtesy of FORD MOTOR CO.
  15. Connect the front driveshaft to the transfer case and install the four new bolts.
  16. Install the rear driveshaft. For additional information, refer to DRIVESHAFT .
  17. If equipped, install the skid plate and the four bolts.
    Fig 16: Identifying Tightening Torque Of Skid Plate Bolts
    G03909842Courtesy of FORD MOTOR CO.
  18. If drained, fill the transfer case. For additional information, refer to TRANSFER CASE DRAINING AND FILLING .
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