Section 07-07A: Transfer Case, Electronic Shift
1996 F-150 4x4 Vehicles with Automatic Transmissions and All Bronco Vehicles Workshop Manual
REMOVAL AND INSTALLATION

Transfer Case, Electronic Shift

Removal

  1.  CAUTION: The three-way catalytic converter is located beside the transfer case. Be careful when working around the three-way catalytic converter because of the extreme high temperatures generated by the three-way catalytic converter.

    Raise the vehicle on a hoist and position suitable safety stands under vehicle.

  1. If so equipped, remove the nuts, bolts and skid plate from the frame (5005).

  1. Place a drain pan under the transfer case (7A195). Remove the drain plug and drain the fluid from the transfer case.

  1.  CAUTION: Do not pull directly on the wires.

    Remove the wire connector from the feed wire harness at the rear of the transfer case. First squeeze the locking tabs, then pull the connectors apart.

  1. NOTE: For detailed instructions on front and rear driveshaft removal, refer to Section 05-01.

    Disconnect the front driveshaft from front case yoke.

  1. Disconnect the rear driveshaft from the rear case yoke.

  1. Disconnect the vent hose from the mounting bracket.

  1. Support the transfer case with a suitable transmission jack such as Rotunda Hi-Lift Jack 164-R3510 or equivalent.

  1. Remove the six bolts retaining the transfer case to the extension housing (7A039).

  1. Slide the transfer case rearward off the transmission output shaft and lower the transfer case from the vehicle. Remove the extension housing gasket from the transfer case and extension housing.

    Transfer Case Installation

Installation

  1. Place a new extension housing gasket between the transfer case and the extension housing.

  1. Raise the transfer case with the transmission jack so that the transmission output shaft aligns with the splined transfer case input shaft (7017). Slide the transfer case forward onto the transmission output shaft and onto the dowel pin. Install the six transfer case retaining bolts to the extension housing. Tighten the bolts to 34-58 Nm (25-43 lb-ft) in the sequence shown.

  1. Remove the transmission jack from the transfer case.

  1. Install the vent hose so that the white marking on the hose aligns with the notch in the mounting bracket.

  1. Connect the rear driveshaft to the case yoke (7B214). Refer to Section 05-01.

  1. Connect the front driveshaft to the front case yoke. Refer to Section 05-01.

  1. Connect the wire connectors on the rear of the transfer case, making sure that the retaining tabs lock.

  1. Install the drain plug and tighten to 9-23 Nm (7-17 lb-ft). Remove the fill plug and install 1.9 liters (2.0 U.S. quarts) of Motorcraft MERCON® automatic transmission fluid ATF XT-2-QDX or equivalent to the bottom of the fill hole. Install fill plug and tighten to 9-23 Nm (7-17 lb-ft).

  1. Install the skid plate, bolts and nuts to the frame and tighten to 20-27 Nm (15-20 lb-ft).

  1. Remove safety stands and lower the vehicle.