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Transfer Case

WARNING: This page is about a different car, the 2002 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
  1. With the vehicle in NEUTRAL, raise and support the vehicle.
  2. Remove the skid plate.
    Fig 1: Removing Skid Plate
    G02153403Courtesy of FORD MOTOR CO.
  3. Remove the damper, if so equipped.
    Fig 2: Removing Damper
    G02153404Courtesy of FORD MOTOR CO.
  4. Disconnect the transfer case harness connector and position it aside.
    Fig 3: Disconnecting Transfer Case Harness Connector
    G02153405Courtesy of FORD MOTOR CO.
  5. If transfer case (7005) disassembly is necessary, remove the drain plug and drain the fluid.
    • Install the drain plug when all of the fluid has drained.
    Fig 4: Removing/Installing Drain Plug
    G02153406Courtesy of FORD MOTOR CO.
    6. CAUTION: Index-mark the front output shaft assembly and the front driveshaft Constant Velocity (CV) joint.
    CAUTION: Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight of the driveshaft can pinch the boot between the shaft and the boot can and cause the boot to tear.
    Fig 5: Disconnecting Front Driveshaft From Transfer Case
    G02153407Courtesy of FORD MOTOR CO.
  6. Disconnect the front driveshaft from the transfer case and position the driveshaft aside.
    1. Index-mark the front output shaft assembly and the front driveshaft Constant Velocity (CV) joint.
    2. Remove and discard the bolts and washers.
    3. Disconnect the front driveshaft from the transfer case and position the driveshaft aside.
    7. CAUTION: Index-mark the front flange on the rear driveshaft and the flange (7B214) on the transfer case.
  7. Remove the rear driveshaft. For additional information, refer to DRIVE SHAFTS .
    8. WARNING: Secure the transfer case to the jack with safety straps.
  8. Position a high lift jack under the transfer case.
  9. Remove the transfer case from the vehicle.
    1. Remove the five bolts retaining the transfer case to the extension housing.
    2. Slide the transfer case rearward and off of the transmission output shaft.
    3. Remove and discard the front extension housing gasket (7086), and clean the mating surfaces.
    Fig 6: Removing Transfer Case
    G02153408Courtesy of FORD MOTOR CO.
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