The transfer case on a 1986 Ford F250 is mounted just behind the transmission. The transfer case on a four-wheel-drive vehicle is designed to split the power generated by the engine and direct it toward the front and rear drive axles. The transfer case also allows the driver to shift between two-wheel drive and four-wheel drive. Overtime, the gears and bearings inside the transfer case can wear out. For most repairs the transfer case must be removed from the vehicle before it can be serviced.
Tools Used: Automotive jack, Jack stands, Wrench set, White paint or chalk, Socket set, Needle-nose pliers
Remove Transfer Case
Remove the Driveshafts
Raise the vehicle and support it with jack stands placed underneath the front and rear axles.
Locate the transfer case drain plug on the bottom of the transfer case. Place a waste oil collection pan underneath the plug and use a wrench to remove the plug. Wait until all the fluid has drained out and reinstall the plug.
Pull the plastic wire connector from the transfer case to disconnect the four-wheel indicator switch wire.
Mark the relationship between the rear driveshaft and the rear axle yoke with white paint or chalk. The driveshaft will be removed, and it must be installed in the same relative position.
Remove the bolts that connect the rear driveshaft to the rear axle yoke.?
Slide the rear driveshaft backward to disengage it from the transfer case and remove it from the vehicle.
Mark the relationship between the front driveshaft and the front axle yoke with white paint or chalk. The driveshaft will be removed, and it must be installed in the same relative position.
Remove the bolts that connect the front driveshaft to the front axle yoke.?
Slide the front driveshaft forward to disengage it from the transfer case. Then remove it from the vehicle.
Remove the Transfer Case
Disconnect the speedometer cable from the transfer case by turning the retaining ring counterclockwise with a wrench.
Remove the shift rods from the transfer case. With a needle nose pliers, remove the retaining clips that secure the shift rods to the transfer case. Pull the shift rods away from the transfer case.
Pull the vent hose off the transfer case.
Support the transfer case by placing a jack underneath it. Raise the jack just enough to take the weight of the transfer case off the transmission.
Remove the bolts that connect the transfer case to the transmission.
Remove the transfer case. Slide the transfer case backward to disengage it from the transmission, lower the jack and slide the transfer case out from underneath the vehicle.
Tips & Warnings
Use a chain to secure the transfer case to the jack while you are removing it.
Always follow the instructions in the owners manual when lifting or lowering a vehicle. Failure to do so could result in injury or death.
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