Transfer Case -3.0L (4V): Removal

WARNING: This page is about a different car, the 2003 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Drain the transfer case. For additional information, refer to TRANSFER CASE DRAINING AND FILLING .
Remove the driveshaft. For additional information, refer to DRIVESHAFT .
Remove the four bolts and the crossmember brace.

Fig 1: Removing Crossmember Brace
Courtesy of FORD MOTOR CO.
Remove the generator. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Disconnect the RH catalyst monitor.
Remove and discard the two nuts and separate the flexible Y-pipe from the manifold.

Fig 2: Removing Flexible Y-Pipe From Manifold
Courtesy of FORD MOTOR CO.
Remove and discard the nuts.
- Discard the gasket.
  
  Fig 3: Remove Manifold Nuts
  Courtesy of FORD MOTOR CO.
Remove and discard the nuts.
- Discard the gasket.
  
  Fig 4: Removing Nut
  Courtesy of FORD MOTOR CO.
Remove the flexible pipe.
- Disconnect the hanger.
  
  Fig 5: Removing Flexible Pipe
  Courtesy of FORD MOTOR CO.
Disconnect the EGR valve to exhaust manifold tube at the manifold.

Fig 6: Disconnect EGR Valve To Exhaust Manifold Tube At Manifold
Courtesy of FORD MOTOR CO.
Disconnect the RH heated oxygen sensor (HO2S). For additional information, refer to HEATED OXYGEN SENSOR .
Remove the RH exhaust manifold.
- Discard the gasket.
  
  Fig 7: Removing RH Exhaust Manifold
  Courtesy of FORD MOTOR CO.
Remove the bracket.
1. Remove the five bolts.
2. Loosen the bolt.
3. Remove the bracket.
  
  Fig 8: Removing Bracket
  Courtesy of FORD MOTOR CO.
Remove the three bolts.

Fig 9: Removing Transfer Case Three Bolts
Courtesy of FORD MOTOR CO.

CAUTION: The linkshaft seal must be replaced whenever the halfshaft or transfer case is removed from the vehicle

NOTE: If necessary, replace the RH differential fluid seal. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION .

Fig 10: Removing Transfer Case

Courtesy of FORD MOTOR CO.

Remove the bolt and the transfer case.