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Transfer Case

WARNING: This page is about a different variant/trim than selected.
Fig 1: Exploded View Of Transfer Case
GF0046981Courtesy of FORD MOTOR CO.
Item Part Number Description
1 4A376 Front driveshaft
2 4602 Rear driveshaft
3 7E063 Skid plate
4 W503932-S Skid plate-to-crossmember bolt (2 required)
5 W503932-S Skid plate-to-frame bolts (4 required)
6 N621945-S Transmission mount nut (2 required)
7 7640124 Crossmember
8 W700140-S Transmission mount bolt (4 required)
9 6068 Transmission mount
10 - Heat shield bolt (2 required)
11 7D494 Vent hose
12 14489 Shift motor electrical connector
13 W637077-S Crossmember bolts (4 required)
14 7A443 Transfer case bolts (9 required)
15 7A195 Transfer case
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
  2. Remove the 2 skid plate-to-crossmember bolts and the 4 skid plate-to-frame bolts and remove the skid plate.
  3. Position a hoist jack on the transmission pan rail.
    4. Fig 2: Jackstand Under Transmission
    GF0022815Courtesy of FORD MOTOR CO.
  4. Drain the fluid if the transfer case is to be disassembled.
    • Install the drain plug when finished draining.
    5. NOTE: Index-mark the driveshaft to maintain initial driveshaft balance during installation.
  5. Remove the front driveshaft. For additional information, refer to DRIVESHAFT article.
    6. NOTE: Index-mark the driveshaft to maintain initial driveshaft balance during installation.
  6. Remove the rear driveshaft. For additional information, refer to DRIVESHAFT article.
  7. Disconnect the shift motor electrical connector and detach the harness connector from the transfer case.
    8. Fig 3: Identifying Shift Motor Electrical Connector & Detach Harness Connector From Transfer Case
    GF0046982Courtesy of FORD MOTOR CO.
  8. Disconnect the vent hose.
  9. Remove the RH exhaust heat shield.
    10. Fig 4: Right Exhaust Heat Shield Bolt
    GF0022544Courtesy of FORD MOTOR CO.
  10. Remove the LH exhaust heat shield bolt and the evaporative emissions canister bolt.
    11. Fig 5: Left Exhaust Heat Shield Bolt & Evaporative Emissions Canister Bolt
    GF0022545Courtesy of FORD MOTOR CO.
  11. Remove the 4 crossmember bolts and nuts.
    12. Fig 6: Locating Crossmember Bolts & Nuts
    GF0046983Courtesy of FORD MOTOR CO.
  12. Remove the 2 transmission mount nuts and the crossmember.
    13. Fig 7: Locating Transmission Mount Nuts & Crossmember
    GF0046984Courtesy of FORD MOTOR CO.
  13. Remove the 4 transmission mount bolts.
    14. Fig 8: Transmission Mount Bolts
    GF0022974Courtesy of FORD MOTOR CO.
  14. Using a suitable transmission jack, position it to the transfer case. Secure the transfer case to the jack with a safety strap.
  15. Remove and discard the 9 transfer case-to-transmission bolts.
    16. NOTE: Using soapy water in a spray bottle, lubricate the transmission mount rubbers on the exhaust.
  16. Separate the transfer case from the transmission and move the transfer case rearward 25.4 mm (1 in). Remove the transmission mount, then move the transfer case rearward off the output shaft and lower it from the vehicle.
    17. Fig 9: Locating Transmission Mount
    GF0046985Courtesy of FORD MOTOR CO.
  17. Remove the transfer case-to-transmission gasket and clean the mating surfaces.
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