Transfer Case: Removal & Installation Ford Escape I

Removal

Note. If the transfer case is leaking automatic transmission fluid, install a new transfer case driven gear seal. Refer to TRANSFER CASE DRIVEN GEAR SEAL .

Vehicles with 3.0L engine

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1. Remove the exhaust system crossover pipe.
2. Remove the heat shield. Remove the bolts. All vehicles
3. Remove the front drive axle intermediate shaft. Refer to «INTERMEDIATE SHAFT»(ref-152646-S30192544382003021800000) .
4. Remove and discard the dust shield.
5. Remove and discard the RH halfshaft seal.

Installation

All vehicles

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1. Using the special tools, install the RH halfshaft seal.
2. Install the dust shield.
3. Install the front drive axle intermediate shaft. Refer to «INTERMEDIATE SHAFT»(ref-152646-S30192544382003021800000) . Vehicles with 3.0L engine
4. Install the heat shield. Install the three bolts.
5. Install the exhaust system crossover pipe. All vehicles
6. Check the transfer case oil level. Refer to «TRANSFER CASE DRAINING AND FILLING»(ref-194831-S18374674612005092900000) .
7. Check the transaxle fluid level. Refer to «CHECKING FLUID LEVEL»(ref-141472-S12034116962002062400000) .

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1. Remove the driveshaft. Refer to DRIVESHAFT .
2. Using the special tool, remove the pinion nut.
3. Using the special tool, remove the companion flange.

1. Using the special tool, install the companion flange.
2. Install the pinion nut.
3. Install the driveshaft. Refer to DRIVESHAFT .

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1. Remove the companion flange. Refer to «TRANSFER CASE REAR OUTPUT SHAFT FLANGE»(ref-194831-S22127340002005092900000) .
2. Remove the companion flange dust shield.

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1. Using the special tool, install the companion flange dust shield.
2. Install the companion flange. Refer to «TRANSFER CASE REAR OUTPUT SHAFT FLANGE»(ref-194831-S22127340002005092900000) .
3. Check the transfer case oil level. Refer to «TRANSFER CASE DRAINING AND FILLING»(ref-194831-S18374674612005092900000) .

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1. Remove the transfer case. Refer to «TRANSFER CASE-3.0L (4V)»(ref-194831-S38510897122005092900000) .
2. Using the special tools, remove the driven gear seal.

1. Using the special tools, install the driven gear seal.
2. Install the transfer case. Refer to «TRANSFER CASE-3.0L (4V)»(ref-194831-S38510897122005092900000) .
3. Fill the transfer case. Refer to «TRANSFER CASE DRAINING AND FILLING»(ref-194831-S18374674612005092900000) .
4. Check the transaxle fluid level. Refer to «CHECKING FLUID LEVEL»(ref-141472-S12034116962002062400000) .

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1. Remove the driveshaft. Refer to DRIVESHAFT .
2. Remove the four bolts and remove the crossmember brace.
3. Remove the two bolts and the two nuts.
4. Remove the transfer case.
5. Remove and discard the O-ring seal.

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1. Disconnect the battery ground cable.
2. Remove the driveshaft. Refer to DRIVESHAFT .
3. Remove the four bolts and the crossmember brace.
4. Remove the generator. Refer to «GENERATOR»(ref-139334-S24621356842002043000000) .
5. Disconnect the RH catalyst monitor.
6. Remove and discard the two nuts and separate the flexible Y-pipe from the manifold.
7. Remove and discard the nuts. Discard the gasket.
8. Remove and discard the nuts. Discard the gasket.
9. Remove the flexible pipe. Disconnect the hanger.
10. Disconnect the EGR valve to exhaust manifold tube at the manifold.
11. Disconnect the RH heated oxygen sensor (HO2S).
12. Remove the RH exhaust manifold. Discard the gasket.
13. Remove the bracket. Remove the five bolts. Loosen the bolt. Remove the bracket.
14. Remove the three bolts.
15. Remove the bolt and the transfer case.

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1. Install a new O-ring seal.
2. Install the transfer case.
3. Install the two bolts and the two nuts.
4. Install the crossmember brace and the four bolts.
5. Install the driveshaft. Refer to DRIVESHAFT .

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1. Install the transfer case. Install the bolts.
2. Install the bolt.
3. Install the bracket and the six bolts.
4. Install the RH exhaust manifold.
5. Connect the RH heated oxygen sensor (HO2S).
6. Connect the EGR to exhaust manifold tube.
7. Install the flex pipe and connect the hanger.
8. Install the gasket and the nuts.
9. Install the gasket and the nuts.
10. Connect the flexible Y-pipe to the exhaust manifold and install the two nuts.
11. Connect the RH catalyst monitor sensor.
12. Install the generator. Refer to «GENERATOR»(ref-139334-S24621356842002043000000) .
13. Instal the crossmember brace and the four bolts.
14. Check the transfer case fluid level. Refer to «Transfer Case Draining and Filling»(ref-194831-S18374674612005092900000) .
15. Install the driveshaft. Refer to DRIVESHAFT .
16. Connect the battery ground cable.
17. Check the transaxle fluid level. Refer to «CHECKING FLUID LEVEL»(ref-141472-S12034116962002062400000) .