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Transfer Case: Removal

WARNING: This page is about a different variant/trim than selected.
  1. Remove the rear driveshaft. For additional information, refer to DRIVESHAFT .
  2. Remove the front driveshaft. For additional information, refer to DRIVESHAFT .
  3. Remove the 4 bolts and the skid plate, if equipped.
    Fig 1: Removing Bolts And Skid Plate
    G03864082Courtesy of FORD MOTOR CO.
  4. Drain the fluid if the transfer case is to be disassembled. For additional information, refer to TRANSFER CASE DRAINING AND FILLING .
  5. Disconnect the vent hose from the transfer case.
    Fig 2: Disconnecting Vent Hose From Transfer Case
    G03864083Courtesy of FORD MOTOR CO.
  6. Position a suitable jack under the transmission.
    Fig 3: Positioning Suitable Jack Under Transmission
    G03864084Courtesy of FORD MOTOR CO.
  7. Position a suitable transmission jack to the transfer case. Securely strap the transfer case to the jack.
    Fig 4: Positioning Suitable Transmission Jack To Transfer Case
    G03864085Courtesy of FORD MOTOR CO.
  8. Remove the 2 transmission insulator-to-transfer case bolts.
  9. Remove the plastic shield on the right side of the crossmember.
    Fig 5: Removing Plastic Shield On Right Side Of Crossmember
    G03864086Courtesy of FORD MOTOR CO.
  10. Remove the 2 crossmember-to-transmission insulator nuts.
  11. Remove the 7 transfer case-to-transmission bolts.
  12. Move the transfer case rearward. Remove the transmission insulator, then move the transfer case forward. Using the jack, tip the rear end of the transfer case downward, remove from the vehicle.
  13. Remove the transfer case-to-transmission gasket and clean the mating surfaces of the transfer case and the transmission.
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