Transfer Case Removal

Transfer Case

All vehicles

1. NOTE: Shift the transfer case to 2W HI.

Raise and support the vehicle.





2. Remove the four bolts and the skid plate, if equipped.

3. NOTE: Index-mark the driveshaft to maintain driveline balance.

Remove the rear driveshaft.





4. Index-mark the front driveshaft to the transfer case flange.





5. NOTE: Support the front driveshaft with wire or a strap.

Remove and discard the four bolts and position the front driveshaft aside.





Manual shift transfer case
6. Remove the manual shift linkage, if equipped.





7. Disconnect the switch electrical connector. Position the wire harness aside.








Electric shift transfer case
8. Disconnect the gear motor encoder assembly electrical connector and the gear motor electrical connector. Position the wire harness aside.





9. Disconnect the transfer case vent hose.





All transfer cases
10. If disassembly is necessary, drain the fluid into a suitable container.
^ Install the plug when finished.





11. Position a suitable high-lift jack under the transfer case and secure it with safety straps.





Excursion vehicles
12. Detach the wire harness from the crossmember.





13. Remove the ten crossmember-to-frame bolts.





F-Super Duty automatic transmission vehicles
14. Remove the four RH crossmember bolts.





15. Remove the three LH crossmember bolts.





All vehicles equipped with automatic transmissions

16. NOTE: Typical is shown.

Remove the nuts and the crossmember.





17. Remove the transmission mount.





18. Position a suitable jack stand under the extension housing.





All vehicles
19. Remove the six transfer case-to-transmission bolts.
20. Separate the transfer case from the extension housing. Pull the transfer case rearward, then lower the transfer case from the vehicle.





21. CAUTION: Carefully clean the gasket surfaces. Nicks and gouges cause fluid leaks.

Remove the transfer case-to-transmission gasket. Clean the mating surfaces, using metal surface cleaner.