Installation

1. Support the transfer case with a hi-lift transmission jack.
- Secure the transfer case to the hi-lift transmission jack with a safety strap.
2. Install a new gasket.





3. Install the transfer case.
- Position the transfer case behind the extension housing.
- Tighten the six bolts.





4. Install the vibration damper.
1 Loosely install the strut bolts.
2 Tighten the transfer case nut.





5. Tighten the strut bolts.





6. Install the vent tube.





7. Remove the wire from the rear driveshaft.





8. Align the marks on the rear transfer case flange and the rear driveshaft.





9. Install the bolts to the rear driveshaft and the rear transfer case flange.
10. Install the front driveshaft.





11. Install the skid plate and bolts.





12. If removed, install the drain plug.





13. Remove the fill plug.
- Fill the transfer case with Motorcraft MERCON(R) Multi-Purpose Automatic Transmission Fluid XT-2-QDX, XT-2-DDX or equivalent MERCON(R) fluid to the bottom of the fill hole.





14. Install the fill plug.