Ford Explorer: Transfer Case / Installation - Transfer Case

Materials

1. NOTICE: Do not over-lubricate the driveshaft components. Using excessive grease may damage the driveshaft components.

   Lubricate the transfer case inner splines with grease.
   Material: Motorcraft® High Temperature 4x4 Front Axle and Wheel Bearing Grease / XG-11 (WSS-M1C267-A1)

1. Connect the transfer case to the transmission output shaft the driveshaft and position the transfer case onto the transmission.
   

1. Install the new transfer case mounting bolts.
   Torque: 159 lb.in (18 Nm)

1. Install the new transfer case mounting bolts.
   Torque: 159 lb.in (18 Nm)

1. Connect the transfer case wiring connector.
   

1. Attach the transfer case vent hose.
   

1. Install the transmission support crossmember.
   Refer to: Transmission Support Insulator (307-01A Automatic Transmission - 10-Speed Automatic Transmission – 10R60, Removal and Installation).
   Refer to: Transmission Support Insulator (307-01B Automatic Transmission - 10-Speed Automatic Transmission – 10R80, Removal and Installation).
   Refer to: Transmission Support Insulator (307-01C Automatic Transmission - 10-Speed Automatic Transmission – 10R80 MHT, Removal and Installation).
   

1. NOTE: Cracks forming in the flex coupling are normal.

   Inspect the flex coupling for damage. If internal windings (threads) are visible, replace the flex coupling if required.
   Refer to: Driveshaft Flexible Coupling (205-01 Driveshaft, Removal and Installation).
   

1. Inspect the driveshaft alignment bushing for damage, clean-off any contamination. If required replace the same.
   Refer to: Driveshaft Alignment Bushing (205-01 Driveshaft, Disassembly and Assembly).
   

1. NOTICE: Make sure the mating surfaces are free of any contamination including removing any blue Loctite from any mating surfaces.

   Clean and inspect the mating surfaces of driveshaft flexible coupling. Clean-off any contamination or excess grease off of transfer case flange and pilot spigot.
   

1. NOTICE: Do not over articulate the driveshaft or damage may occur.

   NOTE: Do not force the flex coupling bushing on the transfer case output shaft or damage will occur.

   
   
   1. Align the index-mark on driveshaft flexible coupling to the transfer case flange.
      
   2. Install the new driveshaft flex coupling to transfer case flange bolts.
      Torque: 81 lb.ft (110 Nm)

1. If equipped, install the transfer case heat shield.
   Torque: 21 lb.ft (28 Nm)

1. Check the transfer case fluid level.
   

1. NOTE: This step is only necessary when a new transfer case is installed.

   Using the scan tool, carry out the Active Torque Coupling Configuration routine. The transfer case X-digit alpha numeric bar code is located on the label attached to the transfer case.
   

1. NOTE: This step is only necessary when a new transfer case is installed.

   Perform the transfer case clutch learn procedure.