How to Remove the Transfer Case on a Ford Ranger Transmissionby Lee Newberry
The Ford Ranger name began as a trim package option that was made available for Ford's full size trucks. In 1983, Ford owned 25 percent of the automobile company Mazda, and had the rights to the Mazda Courier, a compact truck that Ford had been importing since 1972. Ford subsequently changed the Courier name to Ranger and began producing the compact truck. In late 1983, the Ranger came with such options as a six-cylinder engine and a four-wheel-drive system. The transfer case is a main component to the four-wheel-drive system and can be removed with moderate automotive repair knowledge.
Disconnect the negative battery cable from the vehicle battery.
Raise the front of the vehicle off the ground, using a jack. Place two jack stands under the "A" arms located behind the wheel assembly (under the front right and front left of the vehicle).
Lower the front of the vehicle with the jack, until the front end of the vehicle is supported by the jack stands. Remove the jack.
Raise the rear of the vehicle off the ground. Place one jack stand under the rear axle, behind the left wheel assembly. Place the remaining jack stand under the rear axle, behind the right wheel assembly.
Lower the rear of the vehicle with the jack until the vehicle is supported by the jack stands. Remove and set the jack aside.
Locate the transfer case on the transmission assembly: You will see a [drive shaft](https://itstillruns.com/drive-shaft-5387319.html) that comes out of the transfer case that connects to the front axle assembly.
Disconnect the electronic shift wiring harness that connects to the transfer case by squeezing the tabs on the connectors and pulling the connectors apart.
Follow the front drive shaft from the transfer case to the front axle assembly. Remove the four bolts that secure the front drive shaft to the axle assembly, using a socket wrench and socket; turn the bolts counter-clockwise to remove them. Set the bolts aside on a clean rag or towel.
Pull the drive shaft out of the transfer case, by hand, and set the drive shaft assembly aside.
Locate and remove the rear transfer case drive shaft. This will be the drive shaft that connects to the rear end of the vehicle.
Remove all four bolts that connect the rear drive shaft to the transfer case, using a socket wrench and socket; turn each bolt counter-clockwise to remove them. Set the front of the rear drive shaft on the ground, leaving the rear of the drive shaft connected at the rear axle. Set the four bolts aside on a clean rag or towel.
Locate the speedometer drive gear and cable--it is mounted next to the rear drive shaft input on the transfer case. Remove the single bolt that holds in the speedometer drive gear, using a socket wrench and socket and turning the bolt counter-clockwise. Set the bolt aside on a clean rag or towel.
Pull the speedometer drive gear and cable out of the transfer case.
Place a transmission jack under the transfer case assembly and raise the transmission jack until the transfer case assembly is supported by the transmission jack.
Locate the extension housing between the transfer case and transmission (this is where the transfer case is connected to the transmission output shaft). Remove all five bolts that secure the transfer case to the extension housing, using a socket wrench and socket; turn the bolts counter-clockwise to remove them. Set the bolts aside on a clean rag or towel.
Pull the transfer case away from the extension housing and off the transmission output shaft by hand, using the transmission jack to support the weight of the transfer case. Do not use any tools to pry the transfer case apart from the extension housing. Lower the transfer case from the transmission, using the transmission jack.
Remove the gasket that sits between the transfer case and extension housing.
- Keep all removed components and bolts organized on a clean rag or towel for easier cleaning, inspection and installation.
- Always disconnect the negative battery cable when performing any automotive repairs. Make sure the vehicle is securely supported by the jack stands before removing the jack.
Items you will need
- 4 jack stands
- Transmission jack
- Socket wrench
- Clean rag or towel
- "Chilton's Ford Ranger Repair Manual"; Todd W. Stidham, editor; 1999
- red truck front view on metal background image by patrimonio designs from Fotolia.com