Ford F6TZ-7A039-F Transmission Extension Housing

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Prior to condemning the transfer case as the source of a 4WD related problem, first absolve the engine, clutch or transmission, front or rear driveline, front or rear drive axles, front or rear brakes, front locking hubs and front or rear tires and wheels of any contributory effects. It is important to remember that normal driveline windup produced in the 4WD mode can cause hop, skips, bounces, and delayed shifts out of 4WD mode, especially with electronic shifting. This condition can be aggravated by slightly different tire sizes, wear, and loading. Overhauling a transfer case is considered a major repair, and if required, it may be advisable to replace the faulty unit with a new or rebuilt one. Suggestions for DIY repair include drawing a diagram or taking photos or videos during the disassembly process, removing peripheral components before working from the rearmost case forward, checking for missed bolts or snap rings before applying excessive force, paying attention to critical components like oil pumps and shifting mechanisms, anticipating and having replacement parts available, ensuring cleanliness and adequate space during work, pre-lubricating parts with the appropriate fluid, testing the case for any abnormalities before reinstalling, and filling the case with the correct type and quantity of fluid. It is important to avoid testing the transfer case operation in 4WD mode on the street and instead perform testing on dirt, sand, or mud to release torsional driveline windup safely.

Operationally, all transfer cases mentioned perform the same function. In 2WD mode, power is transferred from the transmission to the Input shaft of the transfer case, which then drives the output shaft through a non-functional planetary gear set. Shifting into 4WD mode locks a previously free wheeling gear onto the 2WD output shaft, connecting a second output shaft for the front driveshaft via a multi-row chain. This completes the transfer of power to the front wheels. Shifting into 4WD low activates the transfer case planetary gears for gear reduction of the 2WD output shaft, providing reduced gearing to both axles. The transfer cases differ in the mechanical means used for planetary gear reduction and shift mode mechanisms. Additionally, all transfer cases have an oil pump driven by the rear output shaft to maintain pressure during normal operation and towing.

If both conditions are met, the module activates the spin-up clutch to synchronize the front and rear drive lines.

To remove the transfer case, start by raising the vehicle and supporting it securely on jackstands. Drain the transfer case fluid if necessary. Disconnect the 4WD drive Indicator switch electrical connector or the shift motor harness electrical connector, depending on the model. Remove the speedometer cable and gear assembly if applicable. Disconnect the vent hose from the transfer case. Disconnect the transfer case shift rod link. Remove the skid plate if equipped. Unbolt the heat shield from the transfer case. Disconnect the front and rear driveshafts and tie them securely out of the way. Support the transfer case with a transmission jack. Remove the bolts retaining the transfer case to the transmission adapter. Carefully move the transfer case to the rear until the input shaft clears the adapter, then lower the assembly from the vehicle and remove the gasket between the transfer case and adapter. To install, reverse the removal procedure, making sure to check and fill the transfer case with the correct grade and quantity of lubricant. Tighten the fasteners to the specified torque.

The transfer case should be supported with a transmission jack.

Prior to condemning the transfer case, it is important to absolve other components such as the engine, clutch or transmission, front or rear driveline, front or rear drive axles, front or rear brakes, front locking hubs, and front or rear tires and wheels of any contributory effects.

The Borg Warner 13-56 Electronic Shift system consists of several components including the electronic control module, 4WD selection switch, wire harness, neutral safety switch, transfer case mounted speed sensor, shift motor with integral shift position sensor, electromagnetically actuated front drive gear spin-up clutch, rotary shift cam (drum), and a conventional transfer case. When the 4WD selection switch is pressed, the electronic module checks the shift position sensor and speed sensor to ensure that the vehicle is in 2WD mode and not exceeding the maximum speed for shift on the fly. If both conditions are met, the module activates the spin-up clutch to synchronize the front and rear drive lines. Simultaneously, the shift motor rotates the shift drum to engage the 4WD position, physically connecting the front drive gear to the rear drive output shaft. After the shift is completed, the module verifies the shift mode and illuminates the shift indicator light on the selection switch. For the 4WD low selection, the module confirms that the vehicle is stationary and the transmission is in neutral before commanding the shift motor to rotate the shift drum to engage the 4WD low position, resulting in reduced gearing of the output shaft.

The purpose of the oil pump in the transfer cases is to maintain pressure during normal operation and towing, and it is driven by the rear output shaft.