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Home >> Ford >> 2005 >> Excursion 5.4 L, RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Transfer Case) >> Installation >> Transfer Case
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Transfer Case

WARNING: This page is about a different variant/trim than selected.

    All vehicles 

  1. Install a new mounting gasket.
    Fig 1: Installing New Mounting Gasket
    G03909825Courtesy of FORD MOTOR CO.
    2. CAUTION: Secure the transfer case to the high-lift jack with a safety strap.
    Fig 2: Raising Transfer Case
    G03909818Courtesy of FORD MOTOR CO.
  2. Raise the transfer case into position.
  3. Install the six bolts retaining the transfer case to the extension housing.
    Fig 3: Installing Bolts Retaining Transfer Case To Extension Housing With Torque Specifications
    G03909824Courtesy of FORD MOTOR CO.
  4. Remove the jack stand from the extension housing.
    Fig 4: Removing Jack Stand From Extension Housing
    G03908783Courtesy of FORD MOTOR CO.
  5. Install the transmission mount.
    Fig 5: Installing Transmission Mount With Torque Specifications
    G03908784Courtesy of FORD MOTOR CO.
    6. NOTE: Typical is shown.
    Fig 6: Locating Transmission Insulator-To-Crossmember Support Nuts
    G03908285Courtesy of FORD MOTOR CO.
  6. Position the crossmember and loosely install the two nuts.
  7. Install the ten crossmember bolts.
    Fig 7: Installing Crossmember Bolts With Torque Specifications (1 Of 2)
    G03909832Courtesy of FORD MOTOR CO.
    Fig 8: Installing Crossmember Bolts With Torque Specifications (2 Of 2)
    G03908296Courtesy of FORD MOTOR CO.
  8. Attach the wire harness to the crossmember.
    Fig 9: Attaching Wire Harness To Crossmember
    G03909819Courtesy of FORD MOTOR CO.

    9. All vehicles 

  9. Remove the high-lift jack.
    Fig 10: Removing High-Lift Jack
    G03909818Courtesy of FORD MOTOR CO.
  10. Tighten the transmission mount-to-crossmember nuts.
    Fig 11: Tightening Transmission Mount-To-Crossmember Nuts With Torque Specifications
    G03909000Courtesy of FORD MOTOR CO.

    11. All electric shift transfer cases 

  11. Connect the vent hose.
    Fig 12: Connecting Vent Hose
    G03909816Courtesy of FORD MOTOR CO.
  12. Connect the two gear motor encoder assembly electrical connectors.
    Fig 13: Connecting Two Gear Motor Encoder Assembly Electrical Connectors (1 Of 2)
    G03909814Courtesy of FORD MOTOR CO.
    Fig 14: Connecting Two Gear Motor Encoder Assembly Electrical Connectors (2 Of 2)
    G03909815Courtesy of FORD MOTOR CO.

    13. All manual shift transfer cases 

  13. Connect the 3-position mode switch harness connector.
    Fig 15: Connecting Position Mode Switch Harness Connector
    G03909813Courtesy of FORD MOTOR CO.
  14. Connect the manual shift linkage.

    15. All vehicles 

    CAUTION: Align the index-marks when installing the driveshaft.
    Fig 16: Connecting Front Driveshaft To Transfer Case With Torque Specifications
    G03909841Courtesy of FORD MOTOR CO.
  15. Connect the front driveshaft to the transfer case and install the four new bolts.
  16. Install the rear driveshaft. For additional information, REFER to DRIVESHAFT .
  17. If equipped, install the skid plate and the four bolts.
    Fig 17: Installing Skid Plate With Torque Specifications
    G03909842Courtesy of FORD MOTOR CO.
  18. If drained, fill the transfer case. For additional information, refer to TRANSFER CASE DRAINING AND FILLING  in this article.
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