Ford AA5Z-7005-A Converter Housing Assembly

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Loosen the front wheel lug nuts, raising the front of the vehicle and supporting it securely on jackstands. Have an assistant depress the brake pedal, then break the left and right driveaxle/hub nuts loose for 2007 and earlier models, or just the right driveaxle/hub nut for 2008 and later models. Remove both wheels for 2007 and earlier models or the right wheel for 2008 and later models, and take off the engine undercover and splash shields as necessary for access. For 2007 and earlier models, remove the driveaxles, front and rear exhaust pipe nuts, and the catalytic converter and pipe. Mark the positions of the driveshaft and output shaft flanges before removal, unbolt the driveshaft center support bracket and front portion of the driveshaft, and suspend it from a piece of wire. If equipped, remove the upper transfer case bracket bolts and bracket, then remove the four transfer case bolts. To detach the transfer case, push the output flange upwards and rotate it while removing from the transaxle. For 2008 and later models, mark the positions of the driveshaft and output shaft flanges, unbolt the front portion of the driveshaft, and suspend it. Remove the right driveaxle and intermediate shaft, and the right-side catalytic converter. If equipped, disconnect the oil cooler lines and any electrical connectors or harnesses attached to the transfer case. Remove the roll-restrictor mount fasteners and mount, then the two bolts securing the transfer case to the support bracket, followed by the three bolts securing the transfer case support bracket to the engine. Support the transfer case with a suitable jack, then remove the three transfer case-to-transaxle mounting bolts on the right side and the final two mounting bolts on the left side. To detach the transfer case, push the output flange upwards and rotate it while removing from the transaxle. For installation, reverse the removal steps, ensuring to install a new compression seal to the case, tighten the new driveshaft fasteners and transfer case fasteners to the specified torque, refill the transfer case with the proper type and amount of lubricant, and tighten the wheel lug nuts to the specified torque.

2015 and later four-cylinder engines and alt V6 engines are offered with optional All Wheel Drive (AWD), with the transfer case sending power to the rear differential and rear drive axles. Begin by removing the wheel cover or hub cap, then break the hub nut loose with a socket and large breaker bar, followed by loosening the wheel lug nuts. Raise the front of the vehicle and support it securely on jack stands before removing the right wheel. Unbolt the front portion of the driveshaft and suspend it from a piece of wire, ensuring it does not hang from the center support bearing. For 2015 and later four-cylinder models, remove the Charge Air Cooler (CAC) tube from under the engine, disconnect the electrical connector from the transfer case cooling fan, and then remove the mounting bolt and the fan. For 2015 and later V6 models and 2019 models with an oil cooler, drain the cooling system and disconnect the hoses from the transfer case cooler. Remove the right drive axle and intermediate shaft, as well as the right-side catalytic converter. Next, remove the roll-restrictor mount fasteners and mount, followed by the two bolts securing the transfer case to the support bracket and the three bolts securing the transfer case support bracket to the engine. Support the transfer case with a suitable jack, then work on the right side to remove the three transfer case-to-transaxle mounting bolts, followed by the final two mounting bolts on the left side. To remove the transfer case from the vehicle, rock it until it comes free of the transaxle. Installation is the reverse of removal, ensuring to install a new compression seal to the case, tighten the exhaust system fasteners and NEW driveshaft fasteners to the specified torque, and refill the transfer case with the proper type and amount of fluid. Finally, tighten the wheel lug nuts to the specified torque and fill the cooling system for 2015 and later V6 models.

2015 and later four-cylinder engines and alt V6 engines are offered with optional All Wheel Drive (AWD), with the transfer case sending power to the rear differential and rear drive axles. Begin by removing the wheel cover or hub cap, then break the hub nut loose with a socket and large breaker bar, followed by loosening the wheel lug nuts. Raise the front of the vehicle and support it securely on jack stands before removing the right wheel. Unbolt the front portion of the driveshaft and suspend it from a piece of wire, ensuring it does not hang from the center support bearing. For 2015 and later four-cylinder models, remove the Charge Air Cooler (CAC) tube from under the engine, disconnect the electrical connector from the transfer case cooling fan, and then remove the mounting bolt and the fan. For 2015 and later V6 models and 2019 models with an oil cooler, drain the cooling system and disconnect the hoses from the transfer case cooler. Remove the right drive axle and intermediate shaft, as well as the right-side catalytic converter. Next, remove the roll-restrictor mount fasteners and mount, followed by the two bolts securing the transfer case to the support bracket and the three bolts securing the transfer case support bracket to the engine. Support the transfer case with a suitable jack, then work on the right side to remove the three transfer case-to-transaxle mounting bolts, followed by the final two mounting bolts on the left side. To remove the transfer case from the vehicle, rock it until it comes free of the transaxle. Installation is the reverse of removal, ensuring to install a new compression seal to the case, tighten the exhaust system fasteners and NEW driveshaft fasteners to the specified torque, and refill the transfer case with the proper type and amount of fluid. Finally, tighten the wheel lug nuts to the specified torque and fill the cooling system for 2015 and later V6 models.