Transfer Case

For information on Ford Color Coded Illustrations refer to OEM COLOR CODING

Special Tool(s) / General Equipment 

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: Grease - High Temperature (WSS-M1C267-A1)

   Courtesy of FORD MOTOR COMPANY

2. 1. Remove any contamination or deposits from the transmission housing cover using a plastic scraper or soft bristle brush. Make sure the vent fitting and housing pockets are clean and clear of debris.Use the General Equipment: Plastic Scraper
   2. Clean the transmission to transfer case mating surface. Refer to: RTV Sealing Surface Cleaning and Preparation .

   Courtesy of FORD MOTOR COMPANY

3. NOTE: Apply only enough silicone sealant to seal the transmission case to transfer case mating area, preventing sealant ingress into the seal recess.

   Apply a small bead of silicone sealant to the transmission to transfer case mating surface.

   Material: (WSS-M4G323-A8)

   Courtesy of FORD MOTOR COMPANY

4. Align the transfer case to the transmission output shaft and mate the transfer case against the transmission.

   Courtesy of FORD MOTOR COMPANY

5. Install the new transfer case mounting bolts.

   Torque: 18 Nm

   Courtesy of FORD MOTOR COMPANY

6. Install the new transfer case mounting bolts.

   Torque: 18 Nm

   Courtesy of FORD MOTOR COMPANY

7. Connect the transfer case wiring connector.

   Courtesy of FORD MOTOR COMPANY

8. Attach the transfer case vent hose.

   Courtesy of FORD MOTOR COMPANY

9. Install the transmission support Crossmember. Refer to: Transmission Support Insulator .
10. 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 .

    Courtesy of FORD MOTOR COMPANY

11. NOTE: Inspect the driveshaft bushing for damage and replace if necessary.

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

    Courtesy of FORD MOTOR COMPANY

12. 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.

    Courtesy of FORD MOTOR COMPANY

13. 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: 110 Nm

    Courtesy of FORD MOTOR COMPANY

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

    Torque: 28 Nm

    Courtesy of FORD MOTOR COMPANY

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

    Using the scan tool, carry out the AWD - Active Torque Coupling Configuration routine. The transfer case 16-digit alpha numeric bar code is located on the label attached to the transfer case.

    Courtesy of FORD MOTOR COMPANY

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

    Using the scan tool, carry out the AWD - Relearn Vehicle Data routine. If the routine is unsuccessful, perform the transfer case clutch learn procedure. Refer to: Transfer Case Clutch Learn .