Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Transfer Case
For information on Ford Color Coded Illustrations refer to OEM Color Coding .
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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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NOTE: The help of an assistant will be required.
Position the transfer case to the transmission and onto the output shaft.
- Install new transfer case-to-transmission bolts.
Torque: 168 lb.in (19 Nm)
- Install new transfer case-to-transmission bolts.
Torque: 168 lb.in (19 Nm)
- Refer to: Transmission Support Insulator .
- Install the LH exhaust support bracket and bolt.
Torque: 41 lb.ft (55 Nm)
- Install the transmission support crossmember. Refer to: Transmission Support Crossmember .
- Connect the vent hose to the transfer case.
Vehicles With: 1-Speed Torque On Demand Transfer Case
- Connect the electrical connector and attach the harness retainer clip from the transfer case.
Vehicles With: 2-Speed Torque On Demand Transfer Case
- Connect the shift motor electrical connector.
- Connect the shift motor electrical connector.
All vehicles
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NOTE: Align the index marks made during removal.
Install the rear driveshaft. Refer to: Rear Driveshaft .
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NOTE: Align the index marks made during removal.
Install the front driveshaft. Refer to: Front Driveshaft .
- Check the transfer case fluid level. Refer to: Transfer Case Draining and Filling .
- If equipped. Position the skid plate and install the skid plate bolts.
Torque: 30 lb.ft (40 Nm)
Use the Manual With the Right Hardware
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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