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.

MATERIAL SPECIFICATIONS

Item	Specification
Motorcraft Metal Surface Cleaner ZC-21	WSE-M5B392-A

All vehicles

NOTE: Shift the transfer case to 2H.

With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
Remove the 4 bolts and the skid plate, if equipped.

Fig 1: Locating Skid Plate
Courtesy of FORD MOTOR CO.

NOTE: Index-mark the driveshaft to maintain driveline balance.

Remove the rear driveshaft. For additional information, refer to DRIVESHAFT .
Index-mark the front driveshaft to the transfer case flange.

Fig 2: Locating Index Mark On Driveshaft And Flange
Courtesy of FORD MOTOR CO.

NOTE: Support the front driveshaft with wire or a strap.

Fig 3: Locating Driveshaft Bolts And Alignment Marks

Courtesy of FORD MOTOR CO.

Remove and discard the 4 bolts and position the front driveshaft aside.

Manual shift transfer case

Remove the manual shift linkage, if equipped.

Fig 4: Removing Manual Shift Linkage
Courtesy of FORD MOTOR CO.
Disconnect the switch electrical connector. Position the wire harness aside.

Fig 5: Locating Switch Electrical Connector
Courtesy of FORD MOTOR CO.

Electric shift transfer case

Fig 6: Locating Electric Shift Transfer Case
Courtesy of FORD MOTOR CO.
Disconnect the gear motor encoder assembly electrical connector and the gear motor electrical connector. Position the wire harness aside.

Fig 7: Locating Gear Motor Electrical Connector
Courtesy of FORD MOTOR CO.

All transfer cases

Disconnect the transfer case vent hose.

Fig 8: Locating Transfer Case Vent Hose
Courtesy of FORD MOTOR CO.
If disassembly is necessary, drain the fluid into a suitable container.
- Install the plug when finished.
  
  Fig 9: Locating Drain Plug
  Courtesy of FORD MOTOR CO.
Position a suitable high-lift jack under the transfer case and secure it with safety straps.

Fig 10: Locating Suitable High-Lift Jack Under Transfer Case
Courtesy of FORD MOTOR CO.

Vehicles equipped with automatic transmissions

Remove the 4 RH crossmember bolts.

Fig 11: Locating RH Crossmember Bolts
Courtesy of FORD MOTOR CO.
Remove the 3 LH crossmember bolts.

Fig 12: Locating LH Crossmember Bolts
Courtesy of FORD MOTOR CO.
Remove the transmission mount nuts and the crossmember.

Fig 13: Locating Transmission Mount Nuts And Crossmember
Courtesy of FORD MOTOR CO.
Remove transmission bolts and the transmission mount.

Fig 14: Locating Transmission Bolts And Transmission Mount
Courtesy of FORD MOTOR CO.
Position a suitable jack stand under the extension housing.

Fig 15: Locating Extension Housing
Courtesy of FORD MOTOR CO.

All vehicles

Remove the 6 transfer case-to-transmission bolts.

Fig 16: Locating Transfer Case-To-Transmission Bolts
Courtesy of FORD MOTOR CO.
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 17: Locating Transfer Case-To-Transmission Gasket

Courtesy of FORD MOTOR CO.

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