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Transfer Case

Fig 1: Exploded View Of Transfer Case With Torque Specifications
GF0046986Courtesy 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 bolt (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 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.
  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 push the transfer case to the transmission.
    2. Fig 2: Locating Transmission Mount
    GF0046985Courtesy of FORD MOTOR CO.
    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 20 Nm (15 lb-ft).
  3. Install the 4 transmission mount bolts.
    • Tighten to 90 Nm (66 lb-ft).
    4. Fig 3: Transmission Mount Bolts
    GF0022974Courtesy of FORD MOTOR CO.
  4. Install the crossmember and the 2 transmission mount nuts. Do not tighten at this time.
    5. Fig 4: Locating Transmission Mount Nuts
    GF0046984Courtesy 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).
    6. Fig 5: Locating Crossmember Bolts & Nut
    GF0046983Courtesy of FORD MOTOR CO.
  6. Install the LH exhaust heat shield bolt and the evaporative emissions canister bolt.
    • Tighten to 15 Nm (11 lb-ft).
    7. Fig 6: Left Exhaust Heat Shield Bolt & Evaporative Emissions Canister Bolt
    GF0022545Courtesy of FORD MOTOR CO.
  7. Install the RH exhaust heat shield.
    • Tighten to 15 Nm (11 lb-ft).
    8. Fig 7: Right Exhaust Heat Shield Bolt
    GF0022544Courtesy 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.
    10. Fig 8: Locating Shift Motor Electrical Connector & Harness Connector To Transfer Case
    GF0046982Courtesy of FORD MOTOR CO.
    NOTE: Align the index marks made during removal.
  10. Install the rear driveshaft. For additional information, refer to DRIVESHAFT article.
    11. NOTE: Align the index marks made during removal.
  11. Install the front driveshaft. For additional information, refer to DRIVESHAFT article.
  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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