Disassembly and Assembly

CAUTION: Discard all seals after removing them.

Remove the transfer case from the vehicle. For additional information, refer to TRANSFER CASE .

WARNING: Make sure the holding fixture lock pin is secure.

Fig 1: Securing Transfer Case To A Bench

Courtesy of FORD MOTOR CO.

Using the special tool, secure the transfer case to a bench.
Remove the dampener.
Remove the drain plug and drain the fluid, if not done previously.
- Install the drain plug when finished draining.
Fig 2: Installing Drain Plug
Courtesy of FORD MOTOR CO.
Index-mark the rear output flange and the upper output shaft.

Fig 3: Marking Rear Output Flange And Upper Output Shaft
Courtesy of FORD MOTOR CO.
Remove the components in the order indicated in the following illustration and table.

Fig 4: Manual Transmission Disassembled View
Courtesy of FORD MOTOR CO.

Fig 5: Identifying Manual Transmission Components (Items 1-40)
Courtesy of FORD MOTOR CO.
To assemble, reverse the disassembly procedure.