ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
Transfer Case - Vehicles Built From: 12-2004, Vehicles With: 5-Speed Manual Transmission (AK) > < Transfer Case - Vehicles Built From: 12-2003, Vehicles With: 5-Speed Manual Transmission (AK)

Maverick 2005 (08.2004-)

Transfer Case - Transfer Case—Vehicles Built From: 12/2004, Vehicles With: 4-Speed Automatic Transmission (CD4E) Maverick 2005 (08/2004-)
Installation

Materials
Name
Specification
Motorcraft SAE 75W-140 High Performance Rear Axle Lubricant
XY-75W140-QL
WSL-M2C192-A

 
Item
Part Number
Description
1
7251
Transfer case
2
W706822-S
Transfer case-to-transaxle bolts (3 required)
3
W500121-S
Transfer case-to-transaxle bolt
4
7F496
Transfer case heat shield
5
W500210-S
Transfer case heat shield bolts (3 required)
  1. CAUTION:
    CAUTION:A new transfer case inner halfshaft seal must be installed whenever the intermediate shaft or transfer case is removed from the vehicle.
    NOTE:
    NOTE:If necessary, install a new RH differential fluid seal. For additional information, refer to Section 307-01 Automatic Transmission/Transaxle.
    Position the transfer case to the transaxle.
  1. Install the transfer case-to-engine brace.
  1. Connect the transfer case vent hose.
  1. Install the 4 transfer case-to-transaxle bolts.
    • Tighten to 45 Nm (33 lb-ft).
  1. Install the transfer case heat shield and the 3 transfer case heat shield bolts.
    • Tighten to 14 Nm (10 lb-ft).
  1. Install the generator. For additional information, refer to Section 414-02 Generator and Regulator.

  1. Install the crossmember brace and the 4 bolts.
    • Tighten the bolts to 40 Nm (30 lb-ft).
  1. Install the driveshaft. For additional information, refer to Section 205-01 Driveshaft.
  1. Install the front RH intermediate shaft. For additional information, refer to Section 205-04 Front Drive Halfshafts.
  1. Install the exhaust as required. For additional information, refer to Section 309-00 Exhaust System.
  1. Fill the transfer case. For additional information, refer to Power Transfer Unit (PTU) Draining and Filling — Automatic Transaxle in this section.
  1. Check the transaxle fluid level. For additional information, refer to Section 307-01 Automatic Transmission/Transaxle.

Transfer Case - Vehicles Built From: 12-2004, Vehicles With: 5-Speed Manual Transmission (AK) > < Transfer Case - Vehicles Built From: 12-2003, Vehicles With: 5-Speed Manual Transmission (AK)