Transfer Case

WARNING: This page is about a different variant/trim than selected.

For information on Ford Color Coded Illustrations refer to OEM COLOR CODING .

Special Tool(s) / General Equipment

Rivet Gun

Materials

Name	Specification
Motorcraft® Premium Long-Life Grease XG-1-E1	ESA-M1C75-B

NOTE: Make sure that the mating faces are clean and free of foreign material.

Clean the debris or contamination of the splines.

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NOTE: Do not over-lubricate the driveshaft components. Using excessive grease may damage the driveshaft components.

Lubricate the transfer case inner splines with grease.

Material

: Motorcraft® Premium Long-Life Grease / XG-1-E1 (ESA-M1C75-B)

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Connect the transfer case to the transmission bell housing.

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Install the transfer case mounting bolts.
Torque

: 41 lb.ft (55 Nm)

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Install the transfer case mounting bolts.
Torque

: 41 lb.ft (55 Nm)

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Install the torque arm retainer.
Torque

: 221 lb.ft (300 Nm)

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NOTE: Make sure that the vent hose/valve is not blocked.

Install the transfer case vent hose clamp and retainer.

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Attach the wiring harness retainers.

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- Attach the wiring harness retainers.
- Connect the transfer case electrical connector.
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Install the transmission support crossmember. Refer to: Transmission Support Insulator .
- Install the front floor heat shield and the retainers.
  Torque
  
  : 177 lb.in (20 Nm)
- install the rivets.
  Use the General Equipment: Rivet Gun
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- Install the muffler heat shield and the retainers.
  Torque
  
  : 177 lb.in (20 Nm)
- Install the rivet.
  Use the General Equipment: Rivet Gun
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If equipped
1. Install the muffler heat shield and the retainers.
  Torque
  
  : 177 lb.in (20 Nm)
2. Install the retainers
  Torque
  
  : 20 lb.ft (27 Nm)
3. Remove the rivet.
  Use the General Equipment: Rivet Gun
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Install the muffler bracket and the retainers.
Torque

: 177 lb.in (20 Nm)

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Install the dual catalytic converter y-pipe. Refer to: Dual Catalytic Converter Y-Pipe - AWD - 3.5L EcoBoost (235kW/320PS). Refer to: Dual Catalytic Converter Y-Pipe - AWD - 3.5L Duratec (202kW/275PS).
Install the rear driveshaft.
Fill the transfer case. Refer to: Transfer Case Draining and Filling .
Connect battery terminals.
NOTE: This step is only necessary when a new transfer case is installed.

Using the scan tool, carry out the AWD - Active Torque Coupling Configuration routine. The transfer case 16-digit alpha numeric bar code is located on the label attached to the transfer case.

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NOTE: This step is only necessary when a new transfer case is installed.

Using the scan tool, carry out the AWD - Relearn Vehicle Data routine. If the routine is unsuccessful, perform the transfer case clutch learn procedure. Refer to: Transfer Case Clutch Learn .