Mercury FOTZ-7A039-B Transmission Extension Housing

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On 2011 models, ensure the transfer case is in the 2H position before starting the procedure. Begin by raising the vehicle and securely supporting it on jackstands. If applicable, remove the four skid plate-to-frame bolts and take off the skid plate. For models equipped with a damper, remove it from the transfer case. Drain the transfer case lubricant only if disassembling, then reinstall the drain plug. For electronically controlled models, squeeze the locking tabs labeled PUSH toward each other and pull the electrical connector apart, disconnecting it from the transfer case motor and the connector mounting bracket. If applicable, disconnect the speed sensor electrical connector and speedometer cable from the transfer case. Disconnect the front driveshaft, followed by the rear driveshaft. Disconnect the vent hose from the shift lever bracket or mounting bracket. For manually controlled models, remove the nut from the shift lever and take off the shift lever. Remove the large and small bolts retaining the shifter to the extension housing, then pull on the control lever unit until the bushing slides off the transfer case shift lever pin. Place a transmission jack beneath the transfer case and apply pressure to slightly raise it, using safety chains for stability. Remove the five bolts securing the transfer case to the transmission extension housing, then slide the transfer case rearward off the transmission output shaft and lower it from the vehicle. Remove and discard the gasket between the transfer case and extension housing, cleaning and inspecting the mating surfaces. Installation follows the reverse order of removal with some additions: install a new gasket between the transfer case and extension housing, slide the transfer case onto the transmission output shaft ensuring the splines align until it seats over the dowel pin, and install the five bolts securing the transfer case, tightening them to the specified torque. For manually controlled models, always tighten the large bolt securing the shifter to the extension housing before the small bolt. Install the vent assembly so the white marking on the hose is positioned in the notch in the shift lever bracket or mounting bracket, ensuring the upper end of the vent hose is 3/4 inch above the top of the shifter on manually controlled models. Connect the rear driveshaft to the transfer case output flange and tighten the bolts to the specified torque. Finally, refill the transfer case with the proper type of lubricant.

Use Dexron automatic transmission fluid for refilling or adding fluid to all transfer cases except the Sorg-Warner model 13-59, which is a run-dry unit and contains no fluid. To check the fluid level, position the vehicle on level ground and remove the transfer case fill plug located on the rear of the transfer case; the fluid level should be up to the fill hole. If lubricant does not run out when the plug is removed, add lubricant until it does, then install the fill plug. It is recommended to change the transfer case fluid every 60,000 miles (96,000 km), or sooner if the truck has been driven in deep water. Warming the fluid by driving 15-20 miles on the highway before draining will help it flow better and remove more contaminants. To drain and refill, drive the vehicle to ensure the fluid is at normal operating temperature, then securely raise and support the vehicle on jack stands. Place a drain pan under the transfer case housing below the drain plug, ensuring it is positioned to catch the fluid as it flows outward. Remove the fill plug before the drain plug to avoid complications, then allow the fluid to drain completely. Once drained, install the drain plug securely, fill the transfer case to the proper level with the required fluid, reinstall the filler plug, and finally remove the jack stands to lower the vehicle.

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.

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

Reconnect the negative battery cable.

Place a new gasket between the transfer case and the extension housing.

On manually-controlled models, remove the nut from the shift lever and remove the shift lever.