Ford Explorer: Transfer Case / Removal - Transfer Case
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With the vehicle in NEUTRAL, position it on a hoist.
Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
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If equipped, remove the transfer case heat shield.
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NOTE:
Take extra care not to damage the component.
Position aside and support the rear driveshaft.
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Mark the driveshaft flex coupling to the transfer case flange.
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Remove and discard the driveshaft flex coupling to transfer case flange bolts.
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Remove 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).
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NOTICE:
Make sure that the vent hose/valve is not blocked.
Detach the transfer case vent hose and position aside.
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Disconnect the transfer case wiring connector.
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Remove and discard the transfer case mounting bolts.
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Remove and discard the transfer case mounting bolts.
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Disconnect the transfer case from the transmission output
shaft and the driveshaft. Remove the transfer case from the vehicle.
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Remove and Install a new front driveshaft slip yoke boot.
Refer to: Front Driveshaft Slip Yoke Boot (205-01 Driveshaft, Removal and Installation).
Special Tool(s) /
General Equipment
205-072Universal Flange Holding Wrench
205-1018Installation Tube
205-1067Installer, Output Shaft AWD
205-D027
(D80L-1013-A)
2 or 3 Jaw..
Materials
Name
Specification
Motorcraft® High Temperature 4x4 Front Axle and Wheel Bearing GreaseXG-11
WSS-M1C267-A1
NOTICE:
Do not over-lubricate the driveshaft ..
Other information:
Removal
NOTE:
Removal steps in this procedure may contain installation details.
Remove the front bumper cover.
Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
Remove the 5 headlamp assembly bolts...
Special Tool(s) /
General Equipment
307-346
(T97T-7902-A)
Retainer, Torque ConverterTKIT-1998-LM (NavigatoR)TKIT-1997-F/FLM/LT
Magnetic Socket
Transmission Jack
Wooden Block
Materials
Name
Specification
Motorcraft® Multi-Purpose Grease SprayXL-5-A
ESB-M1C93-B
Motorcraft® MERCON® ULV Automatic Transmission FluidXT-12-QULV
WSS-M2C949-A, MERCON®..
Categories
WARNING: Airbags can kill or injure a child in a child restraint. Never
place a rear-facing child restraint in front of an active airbag. If you must use
a forward-facing child restraint in the front seat, move the seat upon which the
child restraint is installed all the way back.

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