Transfer Case

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

1. If removed, install the vibration damper to the transfer case.

   Torque : 20 Nm

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2. NOTE: The help of an assistant will be required.

   Position the transfer case on the crossmember. Lower the transmission approximately 25.4 mm (1 in).

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3. NOTE: The help of an assistant will be required.

   Position the transfer case to the transmission and onto the output shaft.

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4. NOTE: Do not reuse the old transfer case-to-transmission bolts.

   Install new transfer case-to-transmission bolts.

   Torque : 19 Nm

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5. Install the transmission support insulator. Refer to: Transmission Support Insulator .
6. Install the LH exhaust support bracket and bolt.

   Torque : 55 Nm

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7. Install the transmission support crossmember. Refer to: Transmission Support Crossmember .
8. Connect the vent hose to the transfer case.

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   Vehicles With: 1-Speed Torque On Demand Transfer Case 

9. Connect the electrical connector and attach the harness retainer clip from the transfer case.

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   Vehicles With: 2-Speed Torque On Demand Transfer Case 

10. Connect the shift motor electrical connector.

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11. Connect the shift motor electrical connector.

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    All vehicles 

12. NOTE: Align the index marks made during removal.

    Install the rear driveshaft. Refer to: Rear Driveshaft .

13. NOTE: Align the index marks made during removal.

    Install the front driveshaft. Refer to: FRONT DRIVESHAFT .

14. Check the transfer case fluid level. Refer to: Transfer Case Draining and Filling .
15. If equipped.Position the skid plate and install the skid plate bolts.

    Torque : 40 Nm

Courtesy of FORD MOTOR COMPANY