Removal
All transfer cases1. Note: Shift the transfer case to 2W HI.
Raise and support the vehicle.
2. CAUTION: Index-mark the front and rear driveshafts and flanges to maintain driveline balance.
Disconnect and position the front and rear driveshafts out of the way.
Manual shift transfer case
3. Remove the manual shift linkage.
4. Disconnect the 3 position switch harness connector. Position the harness aside.
Electric shift transfer case
5. Disconnect the gearmotor encoder assembly harness connectors. Position the harness aside.
All transfer cases
6. If disassembly is necessary, remove the drain plug and drain the fluid into a suitable container.
7. Position a suitable high- lift jack under the transfer case and secure it with safety straps.
8. Remove the six bolts retaining the transfer case to the extension housing.
9. CAUTION: Watch for obstructions.
Separate the transfer case from the extension housing, and carefully lower the jack and transfer case.
10. CAUTION: Carefully clean the gasket surfaces. Nicks and gouges cause fluid leaks.
Remove the transfer case-to-transmission gasket, and clean the mating surfaces.
^ Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A.