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Transfer Case

WARNING: This page is about a different variant/trim than selected.
Fig 1: Exploded View Of Transfer Case Components With Torque Specifications
G07458835Courtesy of FORD MOTOR CO.
PARTS DESCRIPTION CHART

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. NOTE: For models with aluminum bolts, a transmission-to-transfer case gasket is not needed. Do not install gasket.
    NOTE: Using soapy water in a spray bottle, lubricate the transmission mount rubbers.

    Position the transfer case to the transmission and onto the output shaft. With the transfer case 25.4 mm (1 in) from the transmission, install the transmission mount, then seat the transfer case to the transmission.

    Fig 2: Locating Transmission Mount Rubbers On Exhaust
    G07458836Courtesy of FORD MOTOR CO.
  2. NOTE: Do not reuse the old transfer case-to-transmission bolts.

    Install the 9 new transfer case-to-transmission bolts.

    • Tighten the bolts evenly in a star pattern to 17 Nm (150 lb-in).
  3. Install the 4 transmission mount bolts.
    • Tighten to 90 Nm (66 lb-ft).
    Fig 3: Locating Transmission Mount Bolts
    G07458837Courtesy of FORD MOTOR CO.
  4. Install the crossmember and the 2 transmission mount nuts. Do not tighten at this time.
    Fig 4: Locating Transmission Mount Nuts
    G07458838Courtesy of FORD MOTOR CO.
  5. Install the 4 crossmember bolts and nuts.
    • Tighten the crossmember bolts to 90 Nm (66 lb-ft).
    • Tighten the transmission mount nuts to 25 Nm (18 lb-ft).
    Fig 5: Locating Crossmember Bolts And Nuts
    G07458839Courtesy of FORD MOTOR CO.
  6. Install the LH exhaust heat shield bolt and the Evaporative Emission (EVAP) canister bolt.
    • Tighten to 15 Nm (133 lb-in).
    Fig 6: Locating LH Exhaust Heat Shield Bolt And Evaporative Emission Canister Bolt
    G07458840Courtesy of FORD MOTOR CO.
  7. Install the RH exhaust heat shield.
    • Tighten to 15 Nm (133 lb-in).
    Fig 7: Locating Exhaust Heat Shield Bolt
    G07458841Courtesy of FORD MOTOR CO.
  8. Connect the vent hose.
  9. Connect the shift motor electrical connector and attach the harness connector to the transfer case.
    Fig 8: Locating Shift Motor Electrical Connector
    G07458842Courtesy of FORD MOTOR CO.
  10. NOTE: Align the index marks made during removal.

    Install the rear driveshaft. For additional information, refer to DRIVESHAFT .

  11. NOTE: Align the index marks made during removal.

    Install the front driveshaft. For additional information, refer to DRIVESHAFT .

  12. Fill the transfer case. For additional information, refer to TRANSFER CASE DRAINING AND FILLING  in the General Procedures portion of this information.
  13. Install the skid plate and the 2 skid plate-to-crossmember bolts and the 4 skid plate-to-frame bolts.
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