Starting on the four-cylinder models from 2004 and earlier, the users need toRemove the right front wheel lug nuts and then lift the front part towards and place and safely support the car on jackstands then remove the wheel. Take off the front part from the driveshaft by unbolting it and they wire it, further take out the right driveaxle and intermediate shaft. Fourth, take out the four bolts of the crossmember and then the crossmember, fifth, undo the two mounting nuts and two mounting bolts on the right side of the transfer case to disengage it. Reversal of these steps is performed while installing to make sure that a new O-ring seal has been placed, the driveshaft and transfer case fasteners have been tightened to the right torque, transfer case has been refilled with the right fluid and the wheel lug nuts tightened. For the V6 models, first of all, try to remove the wheel cover or hub cap, secondly, to ease the operation try to take the hub nut off and finally to remove the wheel lug nuts. Subsequent to lifting the vehicle and providing support, go through similar process of undoing the bolts which connect the driveshaft, right driveaxle, intermediate shaft, exhaust system crossover pipe, and rear exhaust manifold, followed by crossmember and alternator bracket and subsequently, transfer case and mounting bolts. The transfer case can then be removed and installation involves the reverse process with special concern to the O-ring seal and the correct torque setting . For models up to 2008, increase the ride height, then remove the transfer case fluid, driveshaft and crossmember brace and for the MTX models remove the transaxle attachment bolts and nuts, clean the front stud if required and pull the transfer case back to remove it, fit a new O-ring if required. On automatic transaxle models, the right driveaxle, exhaust manifold, heat shield, and the mounting bracket are to be pulled out; the vent tube is disconnected; the transfer case is to be unbolted and removed and if this case is to be replaced the O-ring is to be inserted. As with most repairs, for 2009 and later models, a technician would first raise the vehicle to one side, drain the transfer case fluid then remove the driveshaft and crossmember brace, the right driveaxle, (exhaust manifold, heat shield and mounting bracket,) and finally the transfer case attaching the vent tube lastly.
Posted by FordPartsGiant Specialist 
