Transfer Case
WARNING: This page is about a different car, the 2003 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
The transfer case system consists of a power transfer unit, rear propeller shaft, coupling device and rear axle. The power transfer unit is a gearbox that attaches to a transaxle. The right hand halfshaft passes through the transfer case and engages the differential side gear as in normal 4X2 applications. The transfer case provides power to the rear propshaft through a helical gear spline coupled to the transaxle differential case, a helical gear drop (idler gear) and hypoid/helical ring gear assembly and pinion set.
NOTE:
Repair of the transfer case is limited to seals, gaskets and output flange on automatic transaxle vehicles only. In vehicles equipped with a manual transmission, or if any of the geared components, tapered roller bearings, case cover or internal shafts fail, a new transfer case must be installed.
The transfer case is sealed from the transaxle and has its own oil sump. The transfer case uses SAE 75W-140 synthetic gear lubricant and holds 12 ounces. The transfer case fill plug is located on the housing cover.