Removal

Special Tool:

1. NOTE: Make sure the transfer case is in 2W HI prior to removal.
Raise and support the vehicle.





2. CAUTION: Index mark the front and rear driveshafts to the flanges to maintain proper driveline balance.

Disconnect and position the front and rear driveshafts out of the way.





3. On the manual shift transfer case, remove the manual shift linkage.





4. On the manual shift transfer case, disconnect the 3 position switch harness connector. Position the harness aside.








5. On the electrical shift transfer case, disconnect the gearmotor encoder assembly harness connectors. Position the harness aside.





6. If disassembly is necessary, remove the drain plug and drain the fluid into a suitable container.





7. Position the High-Lift Jack under the transfer case and secure it with safety straps.





8. Remove the six transfer case-to-extension housing mounting bolts.

9. CAUTION: Watch for obstructions.

Separate the transfer case from the extension housing, and carefully lower the jack and transfer case.





10. CAUTION: Use care when cleaning the gasket surfaces. Nicks and gouges can prevent sealing and cause fluid leaks.

Remove the transfer case-to-transmission gasket, and clean the mating surfaces.
^ Use Metal Surface Cleaner F4A3-19A536-RA meeting Ford specification WSE-M513392-A or equivalent.