CAUTION: Three way catalytic converter (TWC) (5E212) is located beside heat shield. Be careful when working around three way catalytic converters because of the extremely high temperatures generated by the three way catalytic converter.Section 07-07C: Transfer Case, Heavy-Duty, Manual Shift | 1996 F-250 and F-350 Except 137-Inch Wheelbase Chassis Cab with E4OD Transmission Workshop Manual |
Removal
CAUTION: Three way catalytic converter (TWC) (5E212) is located beside heat shield. Be careful when working around three way catalytic converters because of the extremely high temperatures generated by the three way catalytic converter.
Raise vehicle on a hoist and position suitable safety stands under vehicle.
Remove skid plate, if equipped.
NOTE: Drain transfer case (7A195) only if transfer case disassembly is required.
Place a drain pan under transfer case, remove drain plug and drain fluid from transfer case.
Disconnect 4WD indicator switch wire connector at transfer case.
Disconnect front driveshaft from front case yoke (7B214).
Disconnect rear driveshaft from rear output shaft case yoke.
CAUTION: When removing the control rod from the gearshift lever (7210), do so very gently so as not to damage the gearshift lever.
Disconnect the control rod between the transfer case shift lever and the gearshift lever.
Support transfer case with Rotunda Hi-Lift Transmission Jack 164-R3510 or equivalent.
Remove the bolts retaining transfer case to extension housing (7A039).
Slide transfer case rearward off the transmission output shaft and lower transfer case from vehicle. Remove extension housing gasket (7086) between transfer case and extension housing.
Installation
Clean transmission and extension housing gasket surfaces and place a new extension housing gasket between transfer case and extension housing.
Raise the transfer case with the transmission jack so that the transmission output shaft aligns with the splined transfer case input shaft. 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 41-54 Nm (30-40 lb-ft) in the sequence shown.
Remove transmission jack from transfer case.
Connect rear driveshaft to rear output shaft case yoke. Refer to Section 05-01.
Attach the control rod between the transfer case shift lever and the gearshift lever.
Connect 4WD indicator switch wire connector at transfer case.
Connect front driveshaft to front output case yoke. Refer to Section 05-01.
Install skid plate to frame (5005). Tighten nuts and bolts to 20-27 Nm (15-20 lb-ft).
Install drain plug and tighten to 9-23 Nm (7-17 lb-ft). Remove fill plug at rear of transfer case and install Motorcraft MERCON® ATF XT-2-QDX or MERCON® equivalent to the bottom of the fill plug hole. Install fill plug and tighten to 9-23 Nm (7-17 lb-ft).
Remove safety stands and lower vehicle.
Transfer Case, 44-07, F-250, F-350 Except 137-Inch Wheelbase Chassis Cab with E4OD Transmission
| Item | Part Number | Description |
|---|---|---|
| 1 | 7A195 | Transfer Case |
| 2 | N804340-S2 | Nut |
| 3 | N620481-S2 | Nut (Alternate) |
| 4 | N605906-S2 | Bolt |
| 5 | 7E063 | Skid Plate |
| 6 | 7A315 | Control Rod |
| 7 | 391219-S2 | Bolt |
| 8 | 7210 | Gearshift Lever |
| 9 | 7003 | Transmission |
| 10 | N605804-S100 | Bolt |
| 11 | 7086 | Extension Housing Gasket |
| 12 | 7A246 | Transmission Breather Tube |
| 13 | 7213 | Gearshift Lever Knob |
| 14 | 55930 | Screw |
| 15 | 7277 | Gearshift Lever Boot |
| A | — | Tighten to 20-27 Nm (15-20 Lb-Ft) |
| B | — | Tighten to 41-54 Nm (30-40 Lb-Ft) |