LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Ford >> 2005 >> Excursion 5.4 L, RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Transfer Case) >> General Procedures >> Transfer Case Shift Lever >> Installation
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Transfer Case Shift Lever: Installation

WARNING: This page is about a different variant/trim than selected.
    CAUTION: Do not tighten the bolt that attaches the transfer case control lever assembly to the transmission case at this time.
    Fig 1: Identifying Rearward (RH/LH) Threaded Hole In Transmission Case
    G03909663Courtesy of FORD MOTOR CO.
  1. Align the new transfer case control lever assembly pivot bolt over the correct mounting hole in the transmission case and start the bolt into the threaded hole by hand.
    1. For vehicles with a gasoline engine and manual transmission, or a diesel engine and manual or automatic transmission, install the new bolt in the forward (LH) threaded hole in the transmission case.
    2. For vehicles with a gasoline engine and automatic transmission, install the new bolt in the rearward (RH) threaded hole in the transmission case.
  2. Position the second bolt in the unused threaded hole in the transmission case.
    • For vehicles with a gasoline engine and manual transmission, or a diesel engine and manual or automatic transmission, position the pin in the rearward (RH) threaded hole in the transmission case.
    • For vehicles with a gasoline engine and automatic transmission, position the pin in the forward (LH) threaded hole in the transmission case.
    3. CAUTION: Verify that the control rod is still attached correctly to the transfer case.
    CAUTION: Verify that the transfer case is still in 4H.
    Fig 2: Connecting Control Rod To Lower Shifter Arm
    G03909661Courtesy of FORD MOTOR CO.
  3. Connect the control rod to the lower shifter arm.
    4. CAUTION: Make sure the transfer case is in 4H. Hold the control lever against the 4H detent while tightening the bolt. This will ensure correct transfer case gear engagement during transfer case operation.
    Fig 3: Tightening Bolt With Torque Specification
    G03909665Courtesy of FORD MOTOR CO.
  4. Hold the control lever against the 4H detent while tightening the bolt.
  5. Lower the vehicle.
  6. Position the shift lever with the bezel and boot assembly and install the bolt.
    Fig 4: Installing Shift Lever With Bezel And Boot Assembly With Torque Specification
    G03909666Courtesy of FORD MOTOR CO.
  7. Position the bezel and boot assembly and install the screws.
    Fig 5: Identifying Bezel And Boot Assembly Screws
    G03909667Courtesy of FORD MOTOR CO.
  8. Verify the shift sequence from 2H to 4L to 2H.
scientia non olet · About LEMON Manuals