Mercury F77Z-7A039-CA Transmission Extension Housing

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Removing the transfer case requires lifting the rig on jack stands and, if it has Automatic Ride Control, turning off the air suspension switch. If models have a skid plate, then first of all the bolts of fastening this plate to the frame and it should be removed. If so required, remove the damper from the transfer case then turn the case to drain the lubricant. For electronically-controlled models-Press the locking tabs on the electrical connecter and pull it to separate it from the transfer case motor as well as the connector mounting bracket. Also, remove the speed sensor electrical connector and speedometer cable if it is available, this in addition to removing the front and rear driveshafts. Take off the vent hose from the shift lever bracket or the mounting bracket, for the models with manual-control; unscrew the nut from the shift lever and pull the lever off. Slacken and then completely withdraw the bolts that attach the shifter to the extension housing; then use a transmission jack to lift the transfer case upward just enough for the safety chains to hold it in place. Take out the five bolts that screw the transfer case onto the transmission extension housing, push the transfer case back off the transmission output shaft and eliminate the gasket laying between the transfer case and transmission extension housing. For installation take the reverse process that of the removal including putting in a new gasket, ensure that the splines are aligned when sliding the transfer case over the transmission output shaft before fixing it using the five bolts and in the right torque sequence. The white marking on the vent assembly must be properly oriented, the rear driveshaft must be mated to the transfer case output flange, and the transfer case should be filled with the correct lubricant.

Remove the nut from the shift lever and remove the shift lever.

The tools necessary for an overhaul include internal and external snap-ring pliers, a bearing puller, a slide hammer, a set of pin punches, a dial indicator, and possibly a hydraulic press. Additionally, a large, sturdy workbench and a large vise will be required.

Remove the five bolts holding the transfer case to the transmission extension housing.