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Transfer Case

WARNING: This page is about a different car, the 2012 Ford Pickup, 2012 Ford F550 Super Duty, 2012 Ford F450 Super Duty, and 2012 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Vehicles with electronic shift transfer case and TorqShift® transmission shown in the illustration, manual shift transfer case and/or TorqShift®6 transmission similar.
Fig 1: Transfer Case Replacement Components With Torque Specifications
G07484235Courtesy of FORD MOTOR CO.
Item Part Number Description
1 - Rear driveshaft bolt (4 required)
2 4602 Rear driveshaft
3 - Front driveshaft bolt (4 required)
4 4817 Front driveshaft
5 7034 Vent hose
6 - Gearmotor encoder electrical connector
7 - Gearmotor electrical connector
8 - Transfer case-to-transmission bolt (6 required for TorqShift® and 11 for TorqShift®6)
9 7A195 Transfer case

All vehicles 

  1. Secure the transfer case to a suitable high-lift transmission jack with a safety strap. Position the transfer case to the extension housing.

    Vehicles with TorqShift® transmission 

    2. NOTE: Hand tighten all transfer case-to-transmission bolts. Torque two bolts to specification that are opposite of each other first. Torque each bolt slowly in steps to avoid binding of the transfer case during tightening. After the first two bolts are torqued to specification, no further tightening sequence is required.
  2. Install the 6 transfer case-to-transmission bolts. Remove the transmission jack.
    • Tighten to 55 Nm (40 lb-ft).

    Vehicles with TorqShift®6 transmission 

    3. NOTE: Hand tighten all transfer case-to-transmission bolts. Torque two bolts to specification that are opposite of each other first. Torque each bolt slowly in steps to avoid binding of the transfer case during tightening. After the first two bolts are torqued to specification, no further tightening sequence is required.
  3. Install the 11 transfer case-to-transmission bolts.
    • Tighten to 55 Nm (40 lb-ft).
  4. Lift the transfer case up and install the transmission support crossmember. For additional information, refer to FULL FRAME AND BODY MOUNTING . Remove the transmission jacks.

    Vehicles with electric shift transfer case 

  5. Connect the gearmotor encoder electrical connector and the gearmotor electrical connector.
    Fig 2: Locating Gearmotor Encoder Electrical Connector And Gearmotor Electrical Connector
    G06779385Courtesy of FORD MOTOR CO.

    Vehicles with manual shift transfer case 

  6. Connect the manual shift linkage to the transmission.
  7. Connect the 3-position mode switch electrical connector.
    Fig 3: Locating 3-Position Mode Switch Electrical Connector
    G06779391Courtesy of FORD MOTOR CO.

    All vehicles 

  8. Connect the vent hose.
    Fig 4: Locating Vent Hose
    G06779386Courtesy of FORD MOTOR CO.
  9. Remove the high-lift jack.

    Vehicles equipped with a flange 

  10. Align the index marks, then connect the rear driveshaft to the transfer case flange. Install the 4 new rear driveshaft bolts.
    • Tighten to 102 Nm (75 lb-ft).
  11. Align the index marks, then connect the front driveshaft to the transfer case flange. Install the 4 new front driveshaft bolts.
    • Tighten to 111 Nm (82 lb-ft).

    Vehicles equipped with a slip yoke 

  12. Install the driveshaft. For additional information, refer to DRIVESHAFT .
  13. If equipped, install the transfer case skid plate and the 4 bolts.
    • Tighten to 24 Nm (18 lb-ft).
      Fig 5: Locating Transfer Case Skid Plate
      G06779101Courtesy of FORD MOTOR CO.
  14. If drained, fill the transfer case to capacity. For additional information, refer to TRANSFER CASE DRAINING AND FILLING .
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