Installation

1. Position the transfer case onto the 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 Vehicle Speed Sensor (VSS) electrical connector.





5. Connect the electric shift motor electrical connector.





6. 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).
7. Install the torsion bars and rear torsion bar support.





8. NOTE: Align the marks on the driveshaft yoke and axle flange so they are installed in their original positions.

Connect the front driveshaft.
- Position the front driveshaft and install the four bolts.





9. Install the front driveshaft shield.
1 Position the front driveshaft shield.
2 Install the front driveshaft shield nuts.





10. Position the rear driveshaft and install the four rear driveshaft flange bolts.
11. Install the crossmembers.





12. If drained, fill the transfer case.
- Use Motorcraft MERCON(R) Automatic Transmission Fluid XT-2-QDX or -DDX or MERCON(R) equivalent.

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

Lower the vehicle.