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Transfer Case

WARNING: This page is about a different variant/trim than selected.
Fig 1: Identifying Transfer Case Components
G06128169Courtesy 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 bolts (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-to-transmission bolts (9 required)
15 7A195 Transfer case
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  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.
    Fig 2: Positioning Hoist Jack On Transmission Pan Rail
    G06127699Courtesy of FORD MOTOR CO.
  4. Drain the fluid if the transfer case is to be disassembled.
    • Install the drain plug when finished draining.
  5. Remove the front driveshaft. For additional information, refer to DRIVESHAFT .
  6. Remove the rear driveshaft. For additional information, refer to DRIVESHAFT .
  7. Disconnect the shift motor electrical connector and detach the harness connector from the transfer case.
    Fig 3: Locating Shift Motor Electrical Connector
    G06128171Courtesy of FORD MOTOR CO.
  8. Disconnect the vent hose.
  9. Remove the RH exhaust heat shield.
    Fig 4: Locating Exhaust Heat Shield Bolt
    G06127308Courtesy of FORD MOTOR CO.
  10. Remove the LH exhaust heat shield bolt and the Evaporative Emission (EVAP) canister bolt.
    Fig 5: Locating Evaporative Emission Canister Bolts
    G06127309Courtesy of FORD MOTOR CO.
  11. Remove the 4 crossmember bolts and nuts.
    Fig 6: Locating Crossmember Bolts And Nuts
    G06128174Courtesy of FORD MOTOR CO.
  12. Remove the 2 transmission mount nuts and the crossmember.
    Fig 7: Locating Transmission Insulator And Retainer Nuts
    G06128175Courtesy of FORD MOTOR CO.
  13. Remove the 4 transmission mount bolts.
    Fig 8: Locating Transmission Insulator And Retainer Bolts
    G06128176Courtesy 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.
    Fig 9: Locating Transmission Mount Rubbers On Exhaust
    G06128177Courtesy of FORD MOTOR CO.
  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. Remove the transfer case-to-transmission gasket and clean the mating surfaces.
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