how to replace transfer case shift motor on 2005 ford f150?

Transfer Case Removal & Installation

CAUTION

The catalytic converter is located beside the transfer case. Due to the extreme high temperatures generated by the converter, be careful when removing the transfer case, or personal injury may result.

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Fluid from the transfer case

   4WD indicator switch wire connector at the transfer case

   Skid plate from the frame, if equipped

   Front driveshaft from the front output yoke

   Rear driveshaft from the rear output shaft yoke

   Speedometer driven gear from the transfer case rear bearing retainer

   Retaining rings and shift rod from the transfer case shift lever
   
   

   

   

   Fig. Transfer case-to-adapter bolt torque sequence-Borg-Warner model 13-45

   Vent hose from the transfer case

   Heat shield from the frame
   
   
3. Support the transfer case with a transmission jack.
4. Remove the bolts retaining the transfer case to the transmission adapter.
5. Lower the transfer case from the vehicle.

To install:

1. When installing place a new gasket between the transfer case and the adapter.
2. Raise the transfer case with the transmission jack so the transmission output shaft aligns with the splined transfer case input shaft. Install the bolts retaining the transfer case to the adapter.
3. Remove the transmission jack from the transfer case.
4. Install or connect the following:
   
   
   Rear driveshaft to the rear output shaft yoke. Tighten the bolts to 15 ft. lbs. (20 Nm).

   Shift lever to the transfer case and install the retaining nut

   Speedometer driven gear to the transfer case

   4WD indicator switch wire connector at the transfer case

   Front driveshaft to the front output yoke. Tighten the bolts to 15 ft. lbs. (20 Nm).

   Heat shield to the frame crossmember and the mounting lug on the transfer case. Install and tighten the retaining bolts.

   Skid plate to the frame
   
   
5. Install the drain plug. Remove the filler plug and install 6 pts. (2.8L) of Dexron®II transmission.
6. Connect the negative battery cable.
   
   
   

   

   Fig. Transfer case-to-adapter bolt torque sequence-Borg-Warner 13-56 electronic and manual shift transfer case used in F-Series

1. Before servicing the vehicle, refer to the Precautions Section.
   
   NOTE

   Shift the transfer case to 2W HI.
   
   
2. Raise and support the vehicle.
3. Remove the four bolts and the skid plate, if equipped.
   
   NOTE

   Index-mark the driveshaft to maintain driveline balance.
   
   
4. Remove the rear driveshaft. Index-mark the front driveshaft to the transfer case flange.
   
   NOTE

   Support the front driveshaft with wire or a strap.
   
   
5. Remove and discard the four bolts and position the front driveshaft aside.

Manual shift transfer case

1. Remove the manual shift linkage, if equipped.
2. Disconnect the switch electrical connector. Position the wire harness aside.

Electric shift transfer case

1. Disconnect the gear motor encoder assembly electrical connector and the gear motor electrical connector. Position the wire harness aside.
2. Disconnect the transfer case vent hose.

All transfer cases

1. If disassembly is necessary, drain the fluid into a suitable container.
2. Install the plug when finished.
3. Position a suitable high-lift jack under the transfer case and secure it with safety straps.

With automatic transmission

1. Remove the four right crossmember bolts.
2. Remove the three left crossmember bolts.
3. Remove the nuts and the crossmember.
4. Remove the transmission mount.
5. Position a suitable jack stand under the extension housing.

All vehicles

1. Remove the six transfer case-to-transmission bolts.
2. Separate the transfer case from the extension housing. Pull the transfer case rearward, then lower the transfer case from the vehicle.
   
   NOTE

   Carefully clean the gasket surfaces. Nicks and gouges cause fluid leaks.
   
   
3. Remove the transfer case-to-transmission gasket. Clean the mating surfaces, using metal surface cleaner.

To install:

1. Install a new mounting gasket.
   
   CAUTION

   Secure the transfer case to the high-lift jack with a safety strap.
   
   
2. Raise the transfer case into position.
3. Install the six bolts retaining the transfer case to the extension housing. Torque to 37 ft. lbs. (50 Nm).

Automatic transmission vehicles

1. Remove the jack stand from the extension housing.
2. Install the transmission mount. Torque to 70 ft. lbs. (95 Nm).
3. Position the crossmember and loosely install the two nuts.
4. Install the three left crossmember bolts. Torque to 52 ft. lbs. (70 Nm).
5. Install the right crossmember bolts. Torque to 52 ft. lbs. (70 Nm).

All vehicles

1. Remove the high-lift jack.

Automatic transmission vehicles

1. Tighten the transmission mount-to-crossmember nuts. Torque to 69 ft. lbs. (92 Nm).

All electric shift transfer cases

1. Connect the vent hose.
2. Connect the two gear motor encoder assembly electrical connectors.

All manual shift transfer cases

1. Connect the 3-position mode switch harness connector.
2. Connect the manual shift linkage.

All vehicles

NOTE

Align the index-marks when installing the driveshaft.

1. Connect the front driveshaft to the transfer case and install the four new bolts. Torque to 82 ft. lbs. (111 Nm).
2. Install the rear driveshaft.
3. If equipped, install the skid plate and the four bolts.
4. If drained, fill the transfer case.

Electronic Shift

Fig. Electronic shift transfer case-2004-05 F-150 Exc. 2004 Heritage Editions

1. Before servicing the vehicle, refer to the Precautions Section.
   
   NOTE

   To maintain initial driveshaft balance, index-mark the rear driveshaft.
   
   
2. Remove the rear driveshaft.
3. Remove the skid plate, if equipped.
4. Drain the fluid if the transfer case is to be disassembled.
5. Disconnect the transfer case shift motor electrical connector.
6. Remove the front driveshaft shield.
7. Remove the front driveshaft.
8. Remove the vent tube.
9. Position a suitable transmission jack to the transfer case. Securely strap the transfer case to the jack.
10. Remove the transfer case.
11. Remove the gasket.
12. Clean the mating surfaces of the transfer case and the transmission.
13. To install, reverse the removal procedure.
14. Tighten the transfer case-to-transmission bolts evenly in a star pattern to 35 ft. lbs. (47 Nm).
15. Fill the transfer case.

Manual Shift

Fig. Mechanical shift transfer case-2004- F-150 exc. 2004 Heritage Editions

1. Before servicing the vehicle, refer to the Precautions Section.
   
   NOTE

   To maintain initial driveshaft balance, index-mark the rear driveshaft.
   
   
2. Remove the rear driveshaft.
3. Remove the skid plate, if equipped.
4. Drain the fluid if the transfer case is to be disassembled.
5. Disconnect the transfer case wire harness
6. Remove the front driveshaft shield.
7. Remove the front driveshaft.
8. Remove the transfer case shift linkage.
9. Remove the vent tube.
10. Position a suitable transmission jack to the transfer case. Securely strap the transfer case to the jack.
11. Remove the transfer case.
12. Clean the mating surfaces of the transfer case and the transmission.
13. To install, reverse the removal procedure.
14. Tighten the transmission-to-transfer case bolts evenly in a star pattern to 35 ft. lbs. (47 Nm).
15. Fill the transfer case.

Fig. Mechanical shift transfer case-F-150

1. Before servicing the vehicle, refer to the Precautions Section.
   
   NOTE

   To maintain initial driveshaft balance, index-mark the rear driveshaft.
   
   
2. Remove the rear driveshaft.
3. Remove the skid plate, if equipped.
4. Drain the fluid if the transfer case is to be disassembled.
5. Disconnect the transfer case wire harness
6. Remove the front driveshaft shield.
7. Remove the front driveshaft.
8. Remove the transfer case shift linkage.
9. Remove the vent tube.
10. Position a suitable transmission jack to the transfer case. Securely strap the transfer case to the jack.
11. Remove the transfer case.
12. Clean the mating surfaces of the transfer case and the transmission.
13. To install, reverse the removal procedure.
14. Tighten the transmission-to-transfer case bolts evenly in a star pattern to 35 ft. lbs. (47 Nm).
15. Fill the transfer case.

With 4R100 Transmission

1. Before servicing the vehicle, refer to the Precautions Section.
2. With the vehicle in Neutral , raise and support the vehicle.
   
   NOTE

   Drain the transfer case if disassembly is required.
   
   
3. Remove the drain plug and drain the transfer case.
4. Remove the skid plate, if equipped.
   
   NOTE

   To maintain initial driveshaft balance, index-mark the rear driveshaft.
   
   
5. Remove the rear driveshaft.
6. Remove the two nuts and the front driveshaft shield.
   
   NOTE

   To maintain initial driveshaft balance, index-mark the front driveshaft.
   
   
7. Remove the front driveshaft.
8. Make preliminary adjustment references. Index-mark the torsion bars to the torsion bar crossmember. Measure and record the torsion bar adjuster bolt length.
9. Remove the torsion bar adjustment nuts. Tighten the tool until the torsion bar adjuster lifts off the adjuster nut.
10. Remove the six bolts, then remove the torsion bar adjusting brackets.
11. Move the torsion bar crossmember rearward. Place a hand under the torsion bar adjusting bracket. The bracket will slide off the torsion bar. Do one side at a time.
12. Position the torsion bar crossmember against the frame support.
13. Pull the torsion bar rearward and separate it from the lower control arm. Remove the right torsion bar only.
14. Remove the torsion bar crossmember.
15. On manual shift vehicles, using the special tool, disconnect the shift rod.
16. On manual shift vehicles, disconnect the 4WD indicator switch electrical connector, if equipped.
17. Disconnect the electric shift motor electrical connector, if equipped.
18. Disconnect the vent hose.
19. Using a suitable jack, support the transfer case. Secure the transfer case to the jack with a safety strap.
20. Remove the two exhaust heat shield-to-crossmember bolts.
21. Loosen, but do not remove, the transmission mount-to-crossmember nuts.
22. Remove the six crossmember-to-frame nuts and bolts.
23. Remove the transmission mount-to-crossmember nuts and the crossmember.
24. Remove the transmission mount and the exhaust hanger.
25. Position a suitable jack stand under the extension housing.
26. Remove the six transfer case-to-transmission bolts and separate the transfer case from the transmission.
27. Lower the transfer case from the vehicle.
28. Remove the transfer case-to-transmission gasket and clean the mounting surfaces.

To install:

1. To install, reverse the removal procedure.
2. Install a new transfer case-to-transmission mounting gasket.
3. Fill the transfer case.
4. Tighten the transfer case-to-transmission bolts evenly in a star pattern to 35 ft. lbs. (47 Nm).
5. Make sure the torsion bar adjuster bolt measurement is equal to the measurement taken during removal.
6. Check the ride height and adjust as necessary.
7. Check the wheel alignment and adjust as necessary.

With 4R70W Transmission

1. Before servicing the vehicle, refer to the Precautions Section.
2. With the vehicle in Neutral , raise and support the vehicle.
   
   NOTE

   Drain the transfer case if disassembly is required.
   
   
3. Remove the drain plug and drain the transfer case.
4. Remove the skid plate, if equipped.
   
   NOTE

   To maintain initial driveshaft balance, index-mark the rear driveshaft.
   
   
5. Remove the rear driveshaft.
6. Remove the two nuts and the front driveshaft shield.
   
   NOTE

   To maintain initial driveshaft balance, index-mark the front driveshaft.
   
   
7. Remove the front driveshaft.
8. Make preliminary adjustment references. Index-mark the torsion bars to the torsion bar crossmember. Measure and record the torsion bar adjuster bolt length.
9. Remove the bolts.
10. Using the special tools, remove the torsion bar adjustment nuts. Tighten the special tool until the torsion bar adjuster lifts off the adjuster nut.
11. Remove the six bolts, then remove the torsion bar adjusting brackets.
12. Move the torsion bar crossmember rearward. Place a hand under the torsion bar adjusting bracket. The bracket will slide off the torsion bar. Do one side at a time. Position the torsion bar crossmember against the frame support.
13. Pull the torsion bar rearward and separate it from the lower control arm. Remove the right torsion bar only.
14. Remove the torsion bar crossmember.
15. On manual shift vehicles, using the special tool, disconnect the shift rod.
16. On manual shift vehicles, disconnect the 4WD indicator switch electrical connector, if equipped.
17. Disconnect the electric shift motor electrical connector, if equipped.
18. Disconnect the vent hose.
19. Using a suitable jack, support the transfer case. Secure the transfer case to the jack with a safety strap.
20. Remove the six transfer case-to-transmission bolts and separate the transfer case from the transmission.
21. Lower the transfer case from the vehicle.
    
    NOTE

    Carefully clean the gasket surfaces. Nicks and gouges cause fluid leaks.
    
    
22. Remove the transfer case-to-transmission gasket, and clean the mating surfaces.

To install:

1. To install, reverse the removal procedure.
2. Install a new transfer case-to-transmission mounting gasket.
3. Fill the transfer case.
4. Tighten the transfer case-to-transmission bolts evenly in a star pattern to 35 ft. lbs. (47 Nm).
5. Make sure the torsion bar adjuster bolt measurement is equal to the measurement taken during removal.
6. Check the ride height and adjust as necessary.
7. Check the wheel alignment and adjust as necessary.

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If you need instructions regarding how to service transfer case shift motor, click this link:---

http://www.therangerstation.com/tech_library/TCaseshiftmotor.htm

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If you like to see the video showing how to replace the t-case shift motor, click the link below:---

http://www.youtube.com/watch?v=9ldrtZODxQ8

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In order to remove and replace the transfer Case shift Motor - you have to spend some time getting it right.

1) remove the 3 bolts on the motor
2) remove the additional bolt on the tail
3) remove the wiring harness plug - we're going to get the old motor out so you can swap the wires somewhere other than under the truck..
4) remove the 2 plugs in the transfer case which have pigtails attached to the main motor harness plug
5) the last wire is a single wire - it comes directly out of the transfer case and does not have a plug on the case assoticated with it.
6) on the motor pigtail - you'll need to take a pair of needle nosed pliers and pull the red center core out so that you can pry the plastic tab away from the pin and pull it out from the backside of the connector.
7) having the center core out allows you to pry away the plastic tabs and pull the wires out the back - pull this tab out and then shift the plastic tabs away from the pins. In this picture you can see they are below the top set of pins and above the second set of pins from the top.
8) Pry the wire coming out of the back of the transfer case which is all alone from the harness first - this will allow you to pull the old motor out and put it alongside the new. This makes the swap way easier.
9) here you go - just move them over one by one - pry the little plastic tab away, then pull straight out - the pins will look like the above - just move them over into the same position on the new Harness.

When you're done - just plug everything back together and make sure you put a bit of form-a-gasket sealant on there to keep dust and junk out. If it has been awhile since your truck has been in 4 wheel drive , cycle it a few times in and out to lube it up again.