Installing new transfer case...any hints or tips? - Ranger-Forums - The Ultimate Ford Ranger Resource


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Old 01-08-2008
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Installing new transfer case...any hints or tips?

My 4x4 control module and transfer case are bad, and i'm getting a new xfer case tonight. I'll be installing it in the near future, are there any hints or tips for installing it, or any other parts that must be replaced when doing so?
The 'new' transfer case is used from another 2001, so i'm hoping it is just a direct replacement.
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Old 01-08-2008
04 EDGE
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make sure that you fill it with mercon V after installing it
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Old 01-08-2008
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Haha that would be bad
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Old 01-08-2008
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i forgot to fill mine after the swap. good thing i only drove it a few miles.
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Old 01-08-2008
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real light transfer case but its always good to have a buddy
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Old 01-08-2008
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2 or 3 people doing the swap is by far easier unless you have a transmission jack....

remember to have the transmission in neutral so you can allign the output shaft splines into the transfer case....
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Old 01-08-2008
D.
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You still on Campus? Need a place to do it? Offer is there. Bring Rudy with ya!
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Old 01-08-2008
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Quote:
Originally Posted by D.
You still on Campus? Need a place to do it? Offer is there. Bring Rudy with ya!
Thanks for the offer once again D!

Actually i'm at home in Pittsburgh, we're on christmas break till monday. I just picked the xfer case up, and i'm going to try putting it on with my dad tonight. I'll post on how it goes.
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Old 01-08-2008
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So far I got my transfer case off. The main case bolts and the bolts connecting the front drive shaft came off pretty easy. The bolts for the rear drive shaft sucked. I have to fill the new/used xfer case and put back on tomorrow.
Also, some ATF came out of the transmission when we got the xfer case off. About a quart or more came out then it stopped. Is that the main ATF in the transmission? How can I check exactly how much to put back in, some fluid leaked on the floor and stuff so I can't measure from the amount that I have in the drain container.
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Old 01-08-2008
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Just pull the tranny fill plug and add fluid with a pump until it starts leaking out of the fill plug.
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Old 01-12-2008
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I finally got the new xfer case on thursday. It was a fairly simple job, other than the weight and awkwardness and some bolts that don't like to be removed or screwed in.
The main problem that I hit was the flange for the rear drive shaft was different on the 2 transfer cases. I had the new case in and didn't realize that the flange was different and the drive shaft wouldn't bolt up. So...I had to take the old one off, but it was rusted on so hard that I could not get it loose. I used everything...pb blaster, impact gun, breaker bar. So I had to take the entire old case to my friend's dad's car shop and have him help me out, he had a hard time too. He ended up getting it off with an impact socket with a 3' breaker bar and "helper pipe" on the breaker bar.
All in all, it was a medium-hard project but it is done. Now I have to get a new 4x4 control module to engage the xfer case.
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