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Transfer Case

WARNING: This page is about a different car, the 2004 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. For additional information, refer to JACKING & LIFTING .
  2. Remove the skid plate.
    Fig 1: Removing Skid Plate
    G03276510Courtesy of FORD MOTOR CO.
  3. Remove the damper, if so equipped.
    Fig 2: Removing Damper
    G03276511Courtesy of FORD MOTOR CO.
  4. Disconnect the transfer case harness connector and position it aside.
    Fig 3: Disconnecting Transfer Case Harness Connector
    G03276512Courtesy 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
      G03276513Courtesy 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.
  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.
      Fig 5: Disconnecting Front Driveshaft From Transfer Case
      G03276514Courtesy of FORD MOTOR CO.
    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 DRIVESHAFT .
    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 From Vehicle
      G03276515Courtesy of FORD MOTOR CO.
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