Lincoln Aviator: Transfer Case / Removal - Transfer Case
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With the vehicle in NEUTRAL, position it on a hoist.
Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
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If equipped, remove the transfer case heat shield.
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NOTE:
Take extra care not to damage the component.
Position aside and support the rear driveshaft.
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Mark the driveshaft flex coupling to the transfer case flange.
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Remove and discard the driveshaft flex coupling to transfer case flange bolts.
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Remove the transmission support insulator.
Refer to: Transmission Support Insulator (307-01A Automatic Transmission - 10-Speed Automatic Transmission – 10R60, Removal and Installation).
Refer to: Transmission Support Insulator (307-01B Automatic Transmission - 10-Speed Automatic Transmission – 10R80 MHT, Removal and Installation).
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NOTICE:
Make sure that the vent hose/valve is not blocked.
Detach the transfer case vent hose and position aside.
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Disconnect the transfer case wiring connector.
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Remove and discard the transfer case mounting bolts.
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Remove and discard the transfer case mounting bolts.
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Disconnect the transfer case from the transmission output
shaft and the driveshaft. Remove the transfer case from the vehicle.
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Remove and Install a new front driveshaft slip yoke boot.
Refer to: Front Driveshaft Slip Yoke Boot (205-01 Driveshaft, Removal and Installation).
Special Tool(s) /
General Equipment
205-072Universal Flange Holding Wrench
205-1018Installation Tube
205-1067Installer, Output Shaft AWD
205-D027
(D80L-1013-A)
2 or 3 Jaw Puller
Removal
With the vehicle in NEUTRAL, position it on a hoist...
Materials
Name
Specification
Motorcraft® High Temperature 4x4 Front Axle and Wheel Bearing GreaseXG-11
WSS-M1C267-A1
NOTICE:
Do not over-lubricate the driveshaft components...
Other information:
Special Tool(s) /
General Equipment
100-001
(T50T-100-A)
Slide Hammer
204-592Separator, Lower Arm Ball JointTKIT-2006C-FFMFLMTKIT-2006C-LMTKIT-2006C-ROW
205-832Remover, HalfshaftTKIT-2006C-FFMFLMTKIT-2006C-LMTKIT-2006C-ROW
303-1246Engine Spreader BarTKIT-2006UF-FLMTKIT-2006UF-ROW
303-1634Lift Eyes (2)TKIT-2014D-ROW3TKIT-2014D-FL_ROW
Tie Rod End Remover
Adjustable Mounting Arm
Cable Ties
Powertrain Jack
Wooden Block
Materials
Name
Specification
Motorcraft® Metal Brake Parts CleanerPM-4-A, PM-4-B
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NOTICE:
The turbocharger compressor vanes can be damaged by even the
smallest particles...
Press the button to cycle through
the four gap settings.
The selected gap appears in the instrument
cluster display as shown by the bars in the
image.
Note: The gap setting is time dependent and
therefore, the distance adjusts with your
vehicle speed...