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: Identifying Transfer Case, Rear Driveshaft, Front Driveshaft And Gearmotor Encoder Electrical Connector

Courtesy 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

NOTE: Shift the transfer case to 2H.

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

Fig 2: Locating Transfer Case Skid Plate
Courtesy of FORD MOTOR CO.

Vehicles equipped with a flange

NOTE: Index-mark the front driveshaft to the transfer case flange.

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

NOTE: Index-mark the rear driveshaft to the transfer case flange.

Remove and discard the 4 rear driveshaft bolts and position the rear driveshaft aside.
Vehicles equipped with a slip yoke
Remove the driveshaft. For additional information, refer to DRIVESHAFT .
Vehicles with manual shift transfer case
Disconnect the manual shift linkage from the transmission.
Disconnect the 3-position mode switch electrical connector.

Fig 3: Locating 3-Position Mode Switch Electrical Connector
Courtesy of FORD MOTOR CO.

Vehicles with electric shift transfer case
Disconnect the gearmotor encoder electrical connector and the gearmotor electrical connector.

Fig 4: Locating Gearmotor Encoder Electrical Connector And Gearmotor Electrical Connector
Courtesy of FORD MOTOR CO.

All vehicles
Disconnect the vent hose.

Fig 5: Locating Vent Hose
Courtesy of FORD MOTOR CO.
If disassembly is necessary, drain the fluid. Install the drain plug when finished.
- Tighten to 27 Nm (20 lb-ft).
  
  Fig 6: Locating Drain Plug
  Courtesy of FORD MOTOR CO.
Vehicles with TorqShift® transmission
Position a suitable high-lift jack to the transfer case and secure it with safety straps.
Remove the 6 transfer case-to-transmission bolts.
Separate the transfer case from the extension housing. Pull the transfer case rearward, then lower the transfer case from the vehicle.
Vehicles with TorqShift®6 transmission
Remove the transmission support crossmember. For additional information, refer to FULL FRAME AND BODY MOUNTING .
Position a suitable high-lift transmission jack to the transfer case and secure it with safety straps.
Remove the 11 transfer case bolts. Pull the transfer case rearward, then lower the transfer case from the vehicle.