# Transfer Case

## Rear Output Shaft Seal

### REMOVAL & INSTALLATION

#### Borg-Warner 44-07 and New Venture Transfer Case

1. Raise and support the truck on jackstands.
2. Remove the rear driveshaft.
3. Remove the yoke nut and washer.
4. Pull the yoke from the shaft.
5. Center-punch the seal and carefully pry it from its bore. Don't scratch the bore!

To install:

6. Clean the bore thoroughly.
7. Coat the OD of the new seal with sealer and the ID with clean Dexron®II ATF.
8. Position the seal squarely in the bore and drive it into place with a seal driver, or similar tool. Don't hammer directly on the seal.
9. Install the washer and yoke. Coat the threads of the shaft with a threadlocking compound. Install the nut and torque it to 150-180 ft. lbs. (203-244 Nm) on the Borg-Warner 44-07 and 186 ft. lbs. (251 Nm) for the New Venture.
10. Install the driveshaft.
11. Lower the vehicle.

#### Borg-Warner 13-56, 44-06 and All Wheel Drive Transfer Case on the Expedition and Navigator

The rear output shaft seal is accessible after the driveshaft is removed

Click to enlarge

Install the rear output shaft seal using a suitable seal driver

Click to enlarge

1. Raise and support the truck on jackstands.
2. Disconnect the driveshaft at the rear axle and slide it from the transfer case.
3. Center-punch the seal and carefully pry it from its bore. Don't scratch the bore!
4. Remove and discard the bushing from the retainer.

To install:

5. Drive a new bushing into place with a seal driver or equivalent tool
6. Position the seal in the retainer so the notch on the seal faces upwards and the drain hole in the rubber boot is downwards. Drive it into place with a seal driver, or similar tool. Don't hammer directly on the seal.
7. Install the driveshaft.
8. Lower the vehicle.

## Front Output Shaft Seal

### REMOVAL & INSTALLATION

#### New Venture Transfer Case (1999-00 Super Duty Models)

1. Raise and support the truck on jackstands.
2. Disconnect the driveshaft at the yoke.
3. Remove the yoke nut and washer.
4. Pull the yoke from the shaft.
5. Center-punch the seal and carefully pry it from its bore. Don't scratch the bore!

To install:

6. Clean the bore thoroughly.
7. Coat the OD of the new seal with sealer and the ID with clean Dexron®II ATF.
8. Position the seal squarely in the bore and drive it into place with a seal driver, or similar tool. Don't hammer directly on the seal.
9. Install the washer and yoke. Coat the threads of the shaft with a threadlocking compound. Install the nut and torque it to 165 ft. lbs. (223 Nm).
10. Install the driveshaft.
11. Lower the vehicle.

#### Except New Venture Transfer Case

Ford's procedure states that the front output shaft seal is replaceable only on disassembly/overhaul of the transfer case assembly.

## Transfer Case Assembly

### REMOVAL & INSTALLATION

#### Borg-Warner Model 13-56

Borg-Warner 13-56 manual shift transfer case installation

Click to enlarge

1. Raise and support the vehicle safely.
2. Drain the fluid from the transfer case.
3. Disconnect the 4WD indicator switch wire connector at the transfer case.
4. Remove the skid plate from the frame, if equipped.
5. Matchmark and disconnect the front driveshaft from the front output yoke.
6. Matchmark and disconnect the rear driveshaft from the rear output shaft yoke.
7. Remove the retaining rings and shift rod from the transfer case shift lever.
8. Disconnect the vent hose from the transfer case.
9. Support the transfer case with a transmission jack.
10. Remove the bolts retaining the transfer case to the extension housing.
11. Lower the transfer case from the vehicle.

To install:

12. When installing place a new gasket between the transfer case and the adapter.
13. Raise the transfer case with the transmission jack so the transmission output shaft aligns with the splined transfer case input shaft.
14. Install the bolts retaining the transfer case to the adapter. Tighten the bolts in sequence to 30-40 ft. lbs. (41-54 Nm).
15. Remove the transmission jack from the transfer case.
16. Connect the rear driveshaft to the rear output shaft yoke.
17. Connect the vent hose to the transfer case.
18. Install the shift lever to the transfer case and install the retaining nut.
19. Connect the 4WD indicator switch wire connector at the transfer case.
20. Connect the front driveshaft to the front output yoke.
21. Install the skid plate to the frame.
22. Install the drain plug.
23. Remove the filler plug and install the proper type and amount of fluid.
24. Lower the vehicle.

#### Borg-Warner 44-06 and All Wheel Drive Transfer Case on the Expedition and Navigator

On manual shift vehicles, use Shift Linkage Insulator Tool T67P-7341-A, or equivalent, to disconnect the shift rod

Click to enlarge

Detach the Vehicle Speed Sensor (VSS) electrical connector

Click to enlarge

On manual shift vehicles, detach the 4WD indicator switch

Click to enlarge

On electric shift vehicles, detach the electric shift motor wiring harness connector

Click to enlarge

Remove the 6 transfer case-to-transmission bolts (3 on each side)

Click to enlarge

1. If equipped with air suspension, deactivate the system.
2. Disconnect the negative battery cable.
3. Raise and safely support the vehicle.
4. Mark the rear driveshaft and flange and remove 4 retaining bolts. Remove the driveshaft.
5. Remove 2 front driveshaft shield bolts and remove the shield.
6. Remove the No. 3 and 4 crossmembers.
7. Mark the front driveshaft and flange and remove 4 retaining bolts. Disconnect the driveshaft from the transfer case and secure out of way.
8. Install Torsion Bar Tool T95T-5310-A with Adapter Plates T96T-5310-A, or equivalents.
9. Tighten the tool until it touches the torsion bar adjuster.
10. Remove the adjuster bolt and nut.
11. Remove the tool and the adjuster.
12. Repeat the procedure for the opposite side.
13. Remove 6 torsion bar crossmember support bolts and remove the support.
14. Remove the torsion bars.
15. Remove 4 transfer case skid plate bolts and remove the skid plate.
16. Detach the Vehicle Speed Sensor electrical harness connector.
17. Detach the electric shift motor electrical harness connector.
18. Support the transfer case with a suitable transmission jack. Remove 6 bolts retaining the transfer case to the transmission and extension housing.
19. Slide the transfer case rearward off the transmission output shaft and lower the transfer case from the vehicle. Remove the gasket from between the transfer case and the extension housing.

To install:

20. Clean the transfer case and transmission extension housing gasket sealing surfaces.
21. Install a new gasket on the front mounting face of the transfer case assembly.
22. Raise the transfer case with the transmission jack so the transmission output shaft aligns with the transfer case input shaft. Slide the transfer case forward onto the transmission output shaft and dowel pin. Install 6 retaining bolts and tighten, in sequence, to 29-40 ft. lbs. (40-54 Nm).
23. Remove the transmission jack.
24. Connect the VSS and electric shift motor electrical harness connectors.
25. Place the slid plate in position and install 4 retaining bolts. Tighten the bolts to 10-13 ft. lbs. (13-17 Nm).
26. Install the torsion bars and rear torsion bar support.
27. Place the front driveshaft to the transfer case noting the index marks made during removal. Tighten the retaining bolts.
28. Place the front driveshaft shield in position and tighten the 3 retaining bolts.
29. Install the rear driveshaft noting the index marks made during removal.
30. Install the No. 3 and 4 crossmembers.
31. If drained, fill the transfer case with the proper type and amount of lubricant.
32. Lower the vehicle.
33. Connect the negative battery cable.
34. Road test the vehicle and verify proper 4WD engagement and operation.
35. If equipped with air suspension, reactivate the system.

#### Borg-Warner 44-07 and New Venture Transfer Case

On manual shift vehicles, disconnect the shift linkage

Click to enlarge

On manual shift vehicles, detach the 3-position switch harness connector

Click to enlarge

On electric shift vehicles, detach the electric shift motor wiring harness connector

Click to enlarge

1. Disconnect the negative battery cable.
2. Raise and safely support the vehicle on jackstands.
3. Drain the transfer case fluid into a large pan or container; dispose of the used fluid.
4. Remove the front and rear driveshafts from the transfer case.
5. On manual shift vehicles, disconnect the shift linkage.
6. On manual shift vehicles, detach the 3-position switch harness connector.
7. On electric shift vehicles, detach the electric shift motor wiring harness connector.
8. Support the transfer case with a hydraulic floor transmission jack, or equivalent. Secure the transfer case to the jack with a safety strap.
9. Remove the 6 transfer case-to-transmission bolts (3 on each side).
10. Lower the transfer case out of the vehicle.

To install:

11. Raise the transfer case into position with the transmission jack.
12. Install the 6 transfer case-to-transmission bolts to 37 ft. lbs. (50 Nm). Remove the transfer case-to-transmission jack securing strap.
13. Remove the jack from under the transfer case.
14. On electric shift models, attach the electric shift motor wiring harness connector.
15. On manual shift vehicles, attach the 3 position switch harness connector.
16. On manual shift vehicles, connect the shift linkage.
17. Install the driveshafts.
18. Fill the transfer case using Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or DDX, or equivalent fluid.
19. Lower the vehicle.
20. Connect the negative battery cable.