Car Fix DIY Videos

http://Ford-trucks.com/how-tos is the leading Ford F-150 and Super Duty truck resource for technical DIY guides. Replacing the transfer case takes some muscle, but you can get it done in a few hours. For the full step-by-step article, please visit http://www.ford-trucks.com/how-tos/a/ford-f150-f250-how-to-replace-your-alternator-361729

The transfer case on your Ford is a heavy piece of equipment your transmission uses to send power to the front and rear wheels. It is located behind the transmission and is not too difficult to remove, but care must be taken to avoid injury when removing this heavy piece of equipment. Aside from weight, it is also located near the exhaust and catalytic converter, so be sure your truck is sufficiently cooled before taking on this task.
Even though their transmissions are different, the Ford F-150 and F-250’s engines have similar transfer case setups. The process for removal and installation is the same.

This moderately difficult job takes about a day and costs from $230 to $500 dollars. A professional will charge around $800 dollars.

This job requires two floor jacks, jack stands, ½ inch ratchet, ⅜ inch ratchet, deep well sockets, WD-40, metal cleaner, a pry bar, drain pans or buckets, new transfer case fluid, and a torque wrench.

Step One – Remove the battery terminals

Disconnect the battery terminals before starting any work.

Step Two – Jack up the rear end

Chock the front wheels. Use jack stands to support and stabilize the truck after lifting the rear end with a floor jack. Use an additional jack or extra jack stands to support the transfer case when you are ready to remove it from the back of the transmission.

Step Three – Drain the transfer case fluid

Place a drain pan under the transfer case. Use a 3/8″ ratchet to loosen the drain plug. The drain plug is located on the bottom left. The top plug is used for filling. Remove the top plug and then the bottom. This will help to drain faster.

Step Four – Remove the drive shafts

Unbolt the rear drive shaft from the transfer case.
There are four 12 millimeter bolts holding this in place.

Once the bolts are removed, pull it from the back so you can pull it free of the transfer case. You might need some additional help here. Repeat this process with the front drive shaft.

When removing the drive shaft, be sure to not damage the splines on the inside of the drive shaft housing.

Step Five – Remove the skid plate if you have one

If you have a skid plate under your transfer case, you will need to remove it for easy access. There are only four 10 millimeter bolts, two on each side connecting the skid plate to the frame.

Step Six – Remove the transfer case

There is a transfer case wire harness that needs to be unhooked. It is a push-pull type of connector and should be easy to disengage.
The transfer case is mounted on the back of the transmission with six 13 millimeter bolts.
The top two on each side are the most difficult to remove and you will do yourself a big favor by using a swivel extension type of ratchet to remove them.

The transfer case is heavy. After removing the bolts, set it on an extra floor jack if you have one and wheel it out. Set the new transfer case and wheel it back under and jack it back up into place.

Step Seven – Clean the metal mating surfaces

Use a metal cleaner to clean the mating surfaces between the truck and the new transfer case. It is probably a good idea to use new gaskets, but if your old gaskets are still in good condition, you may opt to re-use them. Carefully clean the old and make note of the gasket surface. Any nicks or gouges will cause fluid leakage.

Step Eight – Raise the transfer case into position

Use the floor jack to raise the new transfer case into position and re-install the six 13 millimeter bolts to the transmission. Torque the bolts to 37 feet pounds.

Step Nine – Replace the skid plate, drive shafts, and fluid

Replace the skid plate and drive shafts into place. If you marked the shafts, make sure to align them the same way that they were when you removed the old transfer case. Replace the transfer case fluid with a product approved for Ford trucks.