How to Replace Transfer Case on Ford Edge and Lincoln MKX?

The procedure is similar for both ford and Lincoln car models:-----

The details to replace transfer case is as follows:--------

Transfer Case Removal & Installation:-----

NOTE

This procedure covers Removal and Installation of the Power Transfer Unit (PTU).

NOTE

A new intermediate shaft seal and deflector must be installed whenever the intermediate shaft or

1. Power Transfer Unit (PTU) is removed from the vehicle.
2. With the vehicle in NEUTRAL, position it on a hoist.
3. Remove the LH and RH wheel and tire.
4. Remove the intermediate shaft.
   
   NOTE

   Index-mark the driveshaft for installation.
5. Remove the 4 bolts and support the driveshaft with a length of mechanic's wire.
6. Remove the exhaust flexible pipe and the RH catalytic converter.
7. Remove the 2 roll restrictor nuts and the roll restrictor shield
8. Remove the roll restrictor through bolt.
9. Remove the roll restrictor through bolt, 2 roll restrictor bracket bolts and the roll restrictor assembly.
10. Remove the 3 roll restrictor bracket-to-transaxle bolts and the roll restrictor-to-transaxle bracket.
11. Remove the 5 PTU support bracket bolts and the PTU support bracket.
12. Using a long extension, loosen but do not remove the 2 LH side PTU-to-transaxle bolts.
13. Remove the 3 RH side PTU-to-transaxle bolts and the 2 LH side PTU-to-transaxle bolts previously loosened.
14. Separate the PTU from the transaxle and remove it from the vehicle.
    
    NOTE

    A new compression seal must be installed whenever the PTU is removed from the vehicle.
15. Using a suitable tool, remove the compression seal and discard. 
    
    
    
    Fig. Exploded view of the Power Transfer Unit (PTU)

To install:

NOTE

A new compression seal must be installed whenever the Power Transfer Unit (PTU) is removed from the vehicle.

1. Using a suitable tool, install the new compression seal.
   
   NOTE

   A new PTU intermediate shaft seal must be installed whenever the intermediate shaft or PTU is removed from the vehicle.
2. Using a suitable pry bar, move the engine forward. Install a block of wood to hold the engine in the forward position. Install the PTU with the output flange facing the passenger side, filler plug facing upward. Rotate the PTU to the transaxle. Install the 5 PTU-to-transaxle bolts. Tighten to 66 ft. lbs. (90 Nm).
3. Position the PTU support bracket into place and hand tighten the 5 PTU support bracket bolts. Tighten the bolts to the transaxle and to the engine to 52 ft. lbs. (70 Nm).
4. Install the roll restrictor-to-transmission bracket and the 3 roll restrictor bracket-to-transmission bolts and tighten to 66 ft. lbs. (90 Nm).
5. Install the roll restrictor through bolt and the 2 roll restrictor bracket bolts and tighten to 66 ft. lbs. (90 Nm).
6. Install the roll restrictor through bolt and tighten to 76 ft. lbs. (103 Nm).
7. Install the roll restrictor shield and the 2 roll restrictor nuts and tighten to 97 inch lbs. (11 Nm).
8. Install the exhaust flexible pipe and the RH catalytic converter.
9. Install the intermediate shaft.
10. Line up the index marks on the driveshaft to the index marks on the PTU flange made during removal and install the 4 bolts. Tighten the bolts to 52 ft. lbs. (70 Nm).
11. Fill the PTU, if necessary.
12. Install the LH and RH wheel and tire.

These details will help.

Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html