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Home › Ford › 2006 › Expedition RWD › Repair and Diagnosis › External Pages › Different variant/trim › Section 2 (Transfer Case) › Removal › Transfer Case - Navigator

Transfer Case - Navigator

WARNING: This page is about a different variant/trim than selected.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Drain the fluid if the transfer case is to be disassembled.
    • Install the drain plug when finished draining.
      Fig 1: Locating Drain Plug
      G04629033Courtesy of FORD MOTOR CO.
    3. NOTE: The catalytic converter is removed for clarity.
  3. Remove the transfer case-to-transmission brace.
    1. Remove the bolts from the transmission.
      • To install, tighten to 30 N.m (22 lb-ft).
    2. Remove the nuts from the transfer case.
      • To install, tighten to 28 N.m (21 lb-ft).
        Fig 2: Identifying Transmission Case Nuts & Bolts
        G04629034Courtesy of FORD MOTOR CO.
  4. Remove the 2 nuts and the front driveshaft shield.
    • To install, tighten to 18 N.m (13 lb-ft).
      Fig 3: Locating Front Driveshaft Shield Nuts
      G04629035Courtesy of FORD MOTOR CO.
    5. NOTE: Index-mark the driveshaft to maintain initial driveshaft balance during installation.
  5. Remove the front driveshaft. For additional information, refer to REMOVAL AND INSTALLATION .
    6. NOTE: Index-mark the driveshaft to maintain initial driveshaft balance during installation.
  6. Remove the rear driveshaft. For additional information, refer to REMOVAL AND INSTALLATION .
  7. Disconnect the electrical connector.
    Fig 4: Locating Electrical Connector
    G04629036Courtesy of FORD MOTOR CO.
  8. Disconnect the vent hose.
    Fig 5: Identifying Vent Hose
    G04629037Courtesy of FORD MOTOR CO.
    9. NOTE: One transfer case-to-bracket nut is located at the top of the transfer case input flange.
  9. Remove the 3 transfer case-to-bracket nuts.
    • To install, tighten to 70 N.m (52 lb-ft).
      Fig 6: Locating Transfer Case-To-Bracket Nuts
      G04629038Courtesy of FORD MOTOR CO.
  10. Remove the stud.
    Fig 7: Locating Stud
    G04629039Courtesy of FORD MOTOR CO.
  11. Remove the transmission-to-bracket bolts.
    • To install, tighten to 48 N.m (35 lb-ft).
      Fig 8: Locating Transmission-To-Bracket Bolts
      G04629040Courtesy of FORD MOTOR CO.
    12. CAUTION: Never support the transmission from the bottom of the transmission pan.
    Fig 9: Locating Jack Stand For Supporting Transmission
    G04629041Courtesy of FORD MOTOR CO.
  12. Using a suitable jack stand, support the transmission.
    13. CAUTION: Secure the transfer case to the jack with a safety strap.
  13. Using a suitable transmission jack, support the transfer case.
  14. Remove the 2 exhaust heat shield-to-crossmember bolts.
    Fig 10: Locating Exhaust Heat Shield-To-Crossmember Bolts
    G04629042Courtesy of FORD MOTOR CO.
  15. Remove the bolt and the exhaust hanger bracket.
    • To install, tighten to 40 N.m (30 lb-ft).
      Fig 11: Locating Exhaust Hanger Bracket Bolt
      G04629043Courtesy of FORD MOTOR CO.
    16. NOTE: Position a suitable drain pan below the transmission extension housing.
  16. Remove the 6 transfer case-to-transmission extension housing bolts.
    • To install, tighten to 41 N.m (30 lb-ft).
      Fig 12: Locating Transfer Case-To-Transmission Extension Housing Bolts
      G04629044Courtesy of FORD MOTOR CO.
    17. NOTE: Watch for obstructions.
  17. Separate the transfer case from the transmission extension housing, move the transfer case rearward off the output shaft, then lower the transfer case from the vehicle.
    18. CAUTION: Carefully clean the gasket surfaces. Nicks and gouges cause fluid leaks.
    Fig 13: Locating Transfer Case-To-Transmission Gasket Mating Surface
    G04629045Courtesy of FORD MOTOR CO.
  18. Remove the transfer case-to-transmission gasket and clean the mating surfaces.
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