Ford Explorer: Transfer Case / Removal - Transfer Case

Ford Explorer 2020-2024 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 2020-2024 Service Manual: Description and Operation - Rear Drive Axle and Differential

The 8.1-inch and 8.8-inch ring gear open rear differential axle has 3.31, 3.58, and 3.73 gear ratio versions. Rear Drive Axle and Differential The rear axle assembly consists of the following: Integral-type housing hypoid gear design (center of the pinion set below the centerline of the ring gear) Hypoid differential ring gear and pinion consisting of a 8...

Ford Explorer 2020-2024 Service Manual: Removal and Installation - Intermediate Shaft

Removal Remove the front halfshaft. Refer to: Halfshaft (205-04 Front Drive Halfshafts, Removal and Installation). Remove the engine mount LH. Refer to: Engine Mount LH (303-01 Engine) . Detach the front axle assembly vent hose...