Ford E8TZ-7A039-J Transmission Extension Housing

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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.

Before attributing 4WD problems to the transfer case, eliminate any issues from engine, transmission, driveline, axles, brakes, hubs, or tires. Remember, driveline windup in 4WD mode can cause hop, skips, bounces, and delayed shifts, worsened by slightly different tire sizes or wear. If a transfer case overhaul is needed, consider replacement with a new or rebuilt unit. For DIY repairs, document disassembly, ensure cleanliness, pre-lubricate parts, test the case for abnormalities before reinstalling, and use the correct fluid. Avoid testing 4WD mode on the street; instead use dirt, sand, or mud.

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.

The Borg Warner 13-56 Electronic Shift system has components like an electronic control module, 4WD switch, wire harness, neutral safety switch, speed sensor, shift motor, front drive gear clutch, shift cam, and a transfer case. When you press the switch, the module looks at the sensors to make sure the vehicle is in 2WD mode and within the speed limit. If so, the module activates the clutch to synchronize the drive lines and the motor rotates the shift drum to engage 4WD. After the shift, the module verifies the mode and lights up the indicator. For 4WD low, the module ensures the vehicle is stationary and neutral before engaging the shift motor.

The components of the Borg Warner 13-56 Electronic Shift system include 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.

Raise the vehicle and support it securely on jackstands.

The time and money involved in an overhaul are almost sure to exceed the cost of a rebuilt unit.

Some suggestions for DIY repair of a transfer case 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.

The function of all transfer cases mentioned is to transfer power from the transmission to the wheels.

The transfer case should be supported with a transmission jack.

Warm the fluid first so it will flow better, which can be accomplished by 15-20 miles of highway driving.

The procedure should be used if a partial or incomplete engagement of the transfer case shift lever detent is experienced or if the control assembly requires removal.

Connect the rear driveshaft to the output shaft flange and torque the yoke nut to 61-87 ft. lbs.

Unplug the electrical connector from the vehicle speed sensor, the 4WD indicator switch, and the transfer case coil for manual-shift vehicles. For electric-shift vehicles, unplug the electric shift motor connector.

On models so equipped, remove the damper from the transfer case. Some models are equipped with a transfer case damper that must be removed to remove the transfer case.