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Transfer Case

Fig 1: Transfer Case Replacement Components With Torque Specifications
G07953881Courtesy 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
    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.
    Fig 2: Locating Transmission Mount Rubbers On Exhaust
    G06128177Courtesy of FORD MOTOR CO.
  1. 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.
    2. NOTE: Do not reuse the old transfer case-to-transmission bolts.
  2. 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 Insulator And Retainer Bolts
      G06128176Courtesy of FORD MOTOR CO.
  4. Install the crossmember and the 2 transmission mount nuts. Do not tighten at this time.
    Fig 4: Locating Transmission Insulator And Retainer Nuts
    G06128175Courtesy of FORD MOTOR CO.
  5. Install the 4 crossmember bolts and nuts, then tighten the crossmember and transmission mount nuts.
    1. Install the crossmember bolts.
    2. Remove the transmission jack from under the transmission pan rail.
    3. Install the crossmember nuts and tighten to 90 Nm (66 lb-ft).
    4. Tighten the transmission mount nuts to 103 Nm (76 lb-ft).
      Fig 5: Locating Transmission Mount Nuts
      G07953885Courtesy 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 Evaporative Emission Canister Bolts
      G06127309Courtesy 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
      G06127308Courtesy 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
    G06128171Courtesy of FORD MOTOR CO.
    10. NOTE: Align the index marks made during removal.
  10. Install the rear driveshaft. For additional information, refer to DRIVESHAFT .
    11. NOTE: Align the index marks made during removal.
  11. 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  .
  13. Install the skid plate and the 2 skid plate-to-crossmember bolts and the 4 skid plate-to-frame bolts.
    • Tighten to 24 Nm (18 lb-ft).
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