Installation

Special Tools:

1. Position the transfer case onto a jack.
- Use a hi-lift jack.
- Secure the transfer case.
2. Position the transfer case.





3. Install the six transfer case to transmission bolts (three each side).





4. Connect the transfer case coil electrical connector, if equipped.





5. Connect the 4WD indicator switch electrical connector, if equipped.





6. Connect the Output Shaft Speed Sensor (OSS) electrical connector, if equipped.





7. On manual shift transfer case, use the Shift Linkage Remover/Replacer to connect the shift rod.





8. Connect the electric shift motor electrical connector, if equipped.





9. Install the transfer case skid plate.
1 Position the transfer case skid plate.
2 Install the four transfer case skid plate bolts (two each side).
10. Install the torsion bars and rear torsion bar support.





11. NOTE: To maintain initial driveshaft balance, align the front driveshaft yoke and axle flange so they can be installed in their original positions.

Connect the front driveshaft.
1 Position the front driveshaft.
2 Install the four front driveshaft nuts.





12. Install the front driveshaft shield.





13. NOTE: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so they can be installed in their original positions.

Install the rear driveshaft.
1 Position the rear driveshaft.
2 Install the four rear driveshaft flange bolts.





14. NOTE: Make sure drain plug has been installed.

If drained, fill the transfer case.
- Use Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or -DDX or equivalent MERCON fluid.

15. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch.

Lower the vehicle.