Ford F6TZ-7A039-F Transmission Extension Housing

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If the vehicle is equipped with air suspension, turn off the air suspension system using the switch located in the area of the right kick panel. Raise the vehicle and support it securely on jackstands. Remove the transfer skid plate bolts, then take off the skid plate. Drain the transfer case lubricant. Remove the front driveshaft shield, followed by the front and rear driveshafts. Take out the torsion bars and the rear torsion bar support. For manual shift vehicles, disconnect the shift rod. Unplug the electrical connector from the vehicle speed sensor, and for manual-shift vehicles, also unplug the electrical connector from the 4WD indicator switch and the transfer case coil. For electric-shift vehicles, unplug the electric shift motor connector. Support the transfer case with a jack, preferably a special jack designed for this purpose, using safety chains or tie-downs to steady it. Remove the transfer case-to-transmission bolts. Make a final check to ensure all wires and hoses have been disconnected from the transfer case, then move the transfer case and jack toward the rear of the vehicle until the transfer case is clear of the transmission, keeping it level during this process. Once the input shaft is clear, lower the transfer case and remove it from underneath. Installation is the reverse of removal, ensuring to tighten the transmission-to-transfer case bolts to the specified torque.

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.

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.

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 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.

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 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.

The transfer case should be supported with a transmission jack.

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

Remove the front driveshaft shield, then remove the front and rear driveshafts.