Ford Explorer: Transfer Case / Removal - Transfer Case

Ford Explorer 2020-2025 Service Manual / Powertrain / Automatic Transmission / Transfer Case / Removal - Transfer Case

With the vehicle in NEUTRAL, position it on a hoist.
Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).

If equipped, remove the transfer case heat shield.

NOTE: Take extra care not to damage the component.

Position aside and support the rear driveshaft.
1. Mark the driveshaft flex coupling to the transfer case flange.
1. Remove and discard the driveshaft flex coupling to transfer case flange bolts.

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).

NOTICE: Make sure that the vent hose/valve is not blocked.
Detach the transfer case vent hose and position aside.

Disconnect the transfer case wiring connector.

Remove and discard the transfer case mounting bolts.

Remove and discard the transfer case mounting bolts.

Disconnect the transfer case from the transmission output shaft and the driveshaft. Remove the transfer case from the vehicle.

Remove and Install a new front driveshaft slip yoke boot.
Refer to: Front Driveshaft Slip Yoke Boot (205-01 Driveshaft, Removal and Installation).

Removal and Installation - Transfer Case Rear Seal

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..

Installation - Transfer Case

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:

Ford Explorer 2020-2025 Service Manual: Removal and Installation - Rocker Panel

Special Tool(s) / General Equipment Resistance Spotwelding Equipment Spherical Cutter Plasma Cutter Air Body Saw 8 mm Drill Bit MIG/MAG Welding Equipment Spot Weld Drill Bit Locking Pliers Materials Name Specification Seam SealerTA-2-B, 3M™ 08308, LORD Fusor® 805DTM - Removal WARNING: Electric vehicles damaged by a ..

Ford Explorer 2020-2025 Owners Manual: Fuel Shutoff

WARNING: If your vehicle has been involved in a crash, have the fuel system checked. Failure to follow this instruction could result in fire, personal injury or death. Note: When you try to restart your vehicle after a fuel shutoff, the vehicle makes sure that various systems are safe to restart...