Transfer case replacement
Thread Starter
vertical pin buster
Joined: Sep 2013
Posts: 1,411
Likes: 41
From: grant town
Transfer case replacement
Welp. Building off a previous thread my 4x4 in my 03 f150 super crew was not working all the time.
So today coming down a hill I started hearing a scrapping sound. When I went to pull off the road in had no forward gear I tried reverse and couldn't move. But my speedometer said I was doing 70. fooled around with the 4x4 switch and finally got it to go in to 4 low. Then switched back to 2wd but it was stuck in low. I tried to limp it home but just keep acting The t-case was going in to neutral. So now I'm looking for tips to get the old one out. I drained the oil and took the drive shafts out. And most of the bolts broke loose. I'm gonna cut the rivets out of the flat cross member tomorrow and try to wiggle it out that way. Anyone have any tips or advice I'd appreciate it
So today coming down a hill I started hearing a scrapping sound. When I went to pull off the road in had no forward gear I tried reverse and couldn't move. But my speedometer said I was doing 70. fooled around with the 4x4 switch and finally got it to go in to 4 low. Then switched back to 2wd but it was stuck in low. I tried to limp it home but just keep acting The t-case was going in to neutral. So now I'm looking for tips to get the old one out. I drained the oil and took the drive shafts out. And most of the bolts broke loose. I'm gonna cut the rivets out of the flat cross member tomorrow and try to wiggle it out that way. Anyone have any tips or advice I'd appreciate it
Senior Member
Joined: Jul 2010
Posts: 8,544
Likes: 2,552
From: Alaska
Here is the procedure from my Ford Service Manual. I don't know if I actually believe it but will post it for you. I was under the assumption you had to drop the torsion bar mounts at the rear to get it out. This says you don't have to. Well, here it is, so I hope it helps you.
I was right. This is after the torsion bar mount is removed. Here is a YouTube link showing how to R&R our transfer cases. This info below is basically only after doing this.
REMOVAL & INSTALLATION
TRANSFER CASE
Removal
1. Raise vehicle on hoist. Remove skid plate and damper (if equipped). Remove drain plug and drain
transfer case lubricant. Disconnect 4WD indicator switch wire at transfer case (if equipped).
2. Disconnect drive shafts from transfer case. Wire drive shaft out of way. Disconnect speedometer driven
gear or cable from case rear cover (if equipped).
3. Disconnect vent hose from transfer case. Disconnect control rod between shift lever and control lever
assembly. Remove heat shield (if equipped).
4. Support transfer case with a transmission jack. Remove transfer case-to-transmission bolts. Slide transfer
case rearward off transmission, and lower case from vehicle. Remove gasket from between transfer case
and extension housing.
Installation
1. Install new transfer case-to-extension housing gasket. Position transfer case so input shaft splines align
with transmission output shaft. Slide case forward onto transmission output shaft and dowel pin.
2. Install transfer case-to-transmission bolts in sequence. See Fig. 1 . Tighten bolts to specification. See
TORQUE SPECIFICATIONS . Remove jack from transfer case. Install vent assembly so White
marking on hose is in position in notch on shifter. To complete installation, reverse removal procedure.
I was right. This is after the torsion bar mount is removed. Here is a YouTube link showing how to R&R our transfer cases. This info below is basically only after doing this.
REMOVAL & INSTALLATION
TRANSFER CASE
Removal
1. Raise vehicle on hoist. Remove skid plate and damper (if equipped). Remove drain plug and drain
transfer case lubricant. Disconnect 4WD indicator switch wire at transfer case (if equipped).
2. Disconnect drive shafts from transfer case. Wire drive shaft out of way. Disconnect speedometer driven
gear or cable from case rear cover (if equipped).
3. Disconnect vent hose from transfer case. Disconnect control rod between shift lever and control lever
assembly. Remove heat shield (if equipped).
4. Support transfer case with a transmission jack. Remove transfer case-to-transmission bolts. Slide transfer
case rearward off transmission, and lower case from vehicle. Remove gasket from between transfer case
and extension housing.
Installation
1. Install new transfer case-to-extension housing gasket. Position transfer case so input shaft splines align
with transmission output shaft. Slide case forward onto transmission output shaft and dowel pin.
2. Install transfer case-to-transmission bolts in sequence. See Fig. 1 . Tighten bolts to specification. See
TORQUE SPECIFICATIONS . Remove jack from transfer case. Install vent assembly so White
marking on hose is in position in notch on shifter. To complete installation, reverse removal procedure.
Last edited by akdoggie; Oct 31, 2016 at 12:15 AM.
Thread Starter
vertical pin buster
Joined: Sep 2013
Posts: 1,411
Likes: 41
From: grant town
I probably should have mentioned my truck has a body lift. Once I got the bolts out of the tail shaft it slide back and I have to cut part of my tail pipe off and it came right out
Senior Member
Joined: Dec 2015
Posts: 23,191
Likes: 8,622
From: Utah
Here is the procedure from my Ford Service Manual. I don't know if I actually believe it but will post it for you. I was under the assumption you had to drop the torsion bar mounts at the rear to get it out. This says you don't have to. Well, here it is, so I hope it helps you.
I was right. This is after the torsion bar mount is removed. Here is a YouTube link showing how to R&R our transfer cases. This info below is basically only after doing this.
REMOVAL & INSTALLATION
TRANSFER CASE
Removal
1. Raise vehicle on hoist. Remove skid plate and damper (if equipped). Remove drain plug and drain
transfer case lubricant. Disconnect 4WD indicator switch wire at transfer case (if equipped).
2. Disconnect drive shafts from transfer case. Wire drive shaft out of way. Disconnect speedometer driven
gear or cable from case rear cover (if equipped).
3. Disconnect vent hose from transfer case. Disconnect control rod between shift lever and control lever
assembly. Remove heat shield (if equipped).
4. Support transfer case with a transmission jack. Remove transfer case-to-transmission bolts. Slide transfer
case rearward off transmission, and lower case from vehicle. Remove gasket from between transfer case
and extension housing.
Installation
1. Install new transfer case-to-extension housing gasket. Position transfer case so input shaft splines align
with transmission output shaft. Slide case forward onto transmission output shaft and dowel pin.
2. Install transfer case-to-transmission bolts in sequence. See Fig. 1 . Tighten bolts to specification. See
TORQUE SPECIFICATIONS . Remove jack from transfer case. Install vent assembly so White
marking on hose is in position in notch on shifter. To complete installation, reverse removal procedure.
I was right. This is after the torsion bar mount is removed. Here is a YouTube link showing how to R&R our transfer cases. This info below is basically only after doing this.
REMOVAL & INSTALLATION
TRANSFER CASE
Removal
1. Raise vehicle on hoist. Remove skid plate and damper (if equipped). Remove drain plug and drain
transfer case lubricant. Disconnect 4WD indicator switch wire at transfer case (if equipped).
2. Disconnect drive shafts from transfer case. Wire drive shaft out of way. Disconnect speedometer driven
gear or cable from case rear cover (if equipped).
3. Disconnect vent hose from transfer case. Disconnect control rod between shift lever and control lever
assembly. Remove heat shield (if equipped).
4. Support transfer case with a transmission jack. Remove transfer case-to-transmission bolts. Slide transfer
case rearward off transmission, and lower case from vehicle. Remove gasket from between transfer case
and extension housing.
Installation
1. Install new transfer case-to-extension housing gasket. Position transfer case so input shaft splines align
with transmission output shaft. Slide case forward onto transmission output shaft and dowel pin.
2. Install transfer case-to-transmission bolts in sequence. See Fig. 1 . Tighten bolts to specification. See
TORQUE SPECIFICATIONS . Remove jack from transfer case. Install vent assembly so White
marking on hose is in position in notch on shifter. To complete installation, reverse removal procedure.
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Thread Starter
vertical pin buster
Joined: Sep 2013
Posts: 1,411
Likes: 41
From: grant town
New transfer case is in, along with 4 new Universals and 4 quarts 75-140 gear oil and 2 1/2 quarts of mercon V. And a new yolk on the rear drive shaft. Just need to drain and fill the front rear end and test the 4x4.
