Ford Explorer: Transfer Case / Removal - Transfer Case

Ford Explorer 2020-2026 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 2020-2026 Service Manual: Disassembly and Assembly of Subassemblies - Piston

DISASSEMBLY NOTE: If the piston and connecting rod are to be reinstalled, they must be assembled in the same orientation. Mark the piston orientation to the connecting rod reassembly. Remove the piston rings and discard. Remove the piston pin retainers and discard...

Ford Explorer 2020-2026 Service Manual: Diagnosis and Testing - Fog Lamps

Diagnostic Trouble Code (DTC) Chart Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. REFER to: Diagnostic Methods (100-00 General Information, Description and Operation). Diagnostic Trouble Code Chart Module DTC Description Action BCM B1147:1..