Transfer case — removal and installation Ford F150


1. Raise the vehicle and support it securely on jackstands.

2. If equipped, remove the transfer case and transmission skid plate bolts, then remove the skid plates.

3. Drain the transfer case lubricant (see Tune-up and routine maintenance).

4. Remove the front and rear driveshafts (see Driveline).

5. Unplug the electric shift motor connector (see Electric shift motor – replacement). Disconnect the harness clips.

6. Disconnect the vent hose from the top of the transfer case on the transmission side.

7. Support the transfer case with a jack — preferably a special jack with an adapter made for this purpose. Safety chains or tie-downs will help steady the transfer case on the jack.

8. Remove the bolts attaching the exhaust heat shield to the crossmember.

9. Remove the transmission crossmember from the vehicle.

Note: When removing the crossmember it may be necessary to use a knife or similar to cut the heat shield material where the frame and crossmember come together.

10. Remove the driver side exhaust hanger bolt.

11. Remove the transmission mount bolts and remove the mount and bracket from the transfer case.

Ford F150 Transfer case_Transfer case - removal and installation _ Remove and discard the bolts attaching the transfer case to the transmission

Remove and discard the bolts attaching the transfer case to the transmission

12. Remove and discard the nine transfer case bolts-to-transmission bolts.

Note: The bolts attaching the transfer case to the transmission are not to be reused.

13. Make a final check that all wires and hoses have been disconnected from the transfer case, then move the transfer case and jack toward the rear of the vehicle until the transfer case is clear of the transmission. The transmission may require adjustment up or down to remove the transfer case. Keep the transfer case level as this is done. Once the input shaft is clear, lower the transfer case and remove it from under the vehicle.


14. Installation is the reverse of removal. Be sure to install a new mounting gasket and tighten the transmission-to-transfer case bolts to the torque listed in this Chapter’s Specifications.

15. Fill the transfer case with the specified fluid (see Tune-up and routine maintenance), run the engine and check for fluid leaks.

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