Transfer Case

For information on Ford Color Coded Illustrations refer to OEM Color Coding .

Materials 

1. NOTE: Do not over-lubricate the driveshaft components. Using excessive grease may damage the driveshaft components.

   Lubricate the transfer case inner splines with grease.

   Material: Motorcraft® High Temperature 4x4 Front Axle and Wheel Bearing Grease / XG-11 (WSS-M1C267-A1)

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2. Connect the transfer case to the transmission output shaft the driveshaft and position the transfer case onto the transmission.

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3. Install the new transfer case mounting bolts.

   Torque: 159 lb.in (18 Nm)

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4. Install the new transfer case mounting bolts.

   Torque: 159 lb.in (18 Nm)

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5. Connect the transfer case wiring connector.

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6. Attach the transfer case vent hose.

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7. Install the transmission support crossmember. Refer to: Transmission Support Insulator - 10R60 . Refer to: Transmission Support Insulator - 10R80 . Refer to: Transmission Support Insulator - 10R80 MHT .
8. NOTE: Cracks forming in the flex coupling are normal.

   Inspect the flex coupling for damage. If internal windings (threads) are visible, replace the flex coupling if required. Refer to: Driveshaft Flexible Coupling .

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9. Inspect the driveshaft alignment bushing for damage, clean-off any contamination. If required replace the same. Refer to: Driveshaft Alignment Bushing .

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10. NOTE: Make sure the mating surfaces are free of any contamination including removing any blue Loctite from any mating surfaces.

    Clean and inspect the mating surfaces of driveshaft flexible coupling. Clean-off any contamination or excess grease off of transfer case flange and pilot spigot.

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11. NOTE: Do not over articulate the driveshaft or damage may occur.
    NOTE: Do not force the flex coupling bushing on the transfer case output shaft or damage will occur.
    1. Align the index-mark on driveshaft flexible coupling to the transfer case flange.
    2. Install the new driveshaft flex coupling to transfer case flange bolts.

       Torque: 81 lb.ft (110 Nm)

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12. If equipped, install the transfer case heat shield.

    Torque: 21 lb.ft (28 Nm)

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13. Check the transfer case fluid level. Refer to: Transfer Case Fluid Level Check .
14. NOTE: This step is only necessary when a new transfer case is installed.

    Using the scan tool, carry out the Active Torque Coupling Configuration routine. The transfer case X-digit alpha numeric bar code is located on the label attached to the transfer case.

15. NOTE: This step is only necessary when a new transfer case is installed.

    Perform the transfer case clutch learn procedure. Refer to: Transfer Case Clutch Learn .