Mazda B-Series 1998-06

Transfer Case Removal & Installation

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Click image to see an enlarged view

Fig. Exploded view of the 13-54 mechanical shift transfer case



Click image to see an enlarged view

Fig. Exploded view of the 13-54 electronic shift transfer case


CAUTION
The catalytic converter is located beside the transfer case. Be careful when working around the catalytic converter because of the extremely high temperatures generated by the converter.

  1. Disconnect the negative battery cable.
  2.  
  3. Raise the vehicle and support it safely.
  4.  
  5. If so equipped, remove the skid plate from frame.
  6.  
  7. Drain the transfer case.
  8.  
  9. Remove the damper from the transfer case, if so equipped.
  10.  
  11. On electronic shift models, remove the wire connector from the feed wire harness at the rear of the transfer case. Be sure to squeeze the locking tabs, then pull the connectors apart.
  12.  
  13. Disconnect the front driveshaft from the axle input yoke.
  14.  
  15. If equipped, loosen the clamp retaining the front driveshaft boot to the transfer case, and pull the driveshaft and front boot assembly out of the transfer case front output shaft.
  16.  
  17. Disconnect the rear driveshaft from the transfer case output shaft yoke.
  18.  
  19. If equipped, disconnect the speedometer driven gear from the transfer case rear cover.
  20.  
  21. If equipped, disconnect the electrical wire harness plug from the Vehicle Speed Sensor (VSS).
  22.  
  23. Disconnect the vent hose from the mounting bracket.
  24.  
  25. On manual shift models, perform the following:
    1. Remove the shift lever retaining nut and remove the lever.
    2.  
    3. Remove the bolts that retains the shifter to the extension housing. Note the size and location of the bolts to aid during installation. Remove the lever assembly and bushing.
    4.  

  26.  
  27. If equipped, remove the heat shield from the transfer case.
  28.  
  29. Support the transfer case with a transmission jack.
  30.  
  31. Remove the mounting bolts retaining the transfer case to the transmission.
  32.  
  33. Slide the transfer case rearward off the transmission output shaft and lower the transfer case from the vehicle. Remove the gasket or any old sealer from between the transfer case and the transmission.
  34.  

To install:



Click image to see an enlarged view

Fig. Case-to-extension bolt torque sequence-Navajo and B Series Pick-up

  1. Install the heat shield onto the transfer case, if equipped, and place a new gasket or silicone sealer between the transfer case and adapter.
  2.  
  3. Raise the transfer case with a suitable transmission jack or equivalent, raise it high enough so that the transmission output shaft aligns with the splined transfer case input shaft.
  4.  
  5. Slide the transfer case forward on to the transmission output shaft and onto the dowel pin. Install transfer case retaining bolts and torque them to specification. Tighten the mounting bolts to 35-46 ft. lbs. (47-63 Nm) on Navajo/B Series Pick-ups and 27-39 ft. lbs. (37-52 Nm) on MPVmodels.
  6.  
  7. The remainder of the installation procedure is the reverse of removal. Check the fluid level and, if necessary, top off with the correct amount and type of transfer case fluid.
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Place the transmission in neutral.
  4.  
  5. Remove or disconnect the following:

    Skid plate
     
    Damper
     
    Transfer case harness connector and position it aside
     

  6.  
  7. If transfer case (7005) disassembly is necessary, remove the drain plug and drain the fluid.
    NOTE
    Index-mark the front output shaft assembly and the front driveshaft constant velocity (CV) joint. Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight of the driveshaft can pinch the boot between the shaft and the boot can and cause the boot to tear.


    NOTE
    Index-mark the front flange on the rear driveshaft and the flange on the transfer case.


    NOTE
    Secure the transfer case to the jack with safety straps.



    Front driveshaft from the transfer case and position the driveshaft aside. Remove and discard the bolts and washers.
     



    Rear driveshaft
     

  8.  
  9. Position a high lift jack under the transfer case.
  10.  
  11. Remove or disconnect the following:

    Five bolts retaining the transfer case to the extension housing
     
    Transfer case rearward and off of the transmission output shaft
     

  12.  
  13. Remove and discard the front extension housing gasket and clean the mating surfaces.
  14.  

To install:

  1. Installation is the reverse of removal. Take note of the following:

    Install the transfer case with a new gasket.
     
    Tighten the bolts that retain the transfer case to the extension housing in a clockwise direction beginning with the upper LH bolt.
     
    Install the front and the rear driveshafts with new bolts. If new bolts are not available, coat the threads of the original bolts with Threadlock and Sealer E0AZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5.
     
    When installing the front driveshaft, always connect it to the axle first and then connect it to the transfer case.
     
    Align the index marks when installing the front and rear driveshafts.
     

  2.  
  3. Observe the following torques:

    Nut retaining the flange to the rear output shaft: 262 ft. lbs. (355Nm)
     
    Bolt retaining the rear driveshaft to the flange: 82 ft. lbs. (111Nm)
     
    Bolt retaining the motor assembly and connector to the transfer case cover: 89 inch lbs. (10Nm)
     
    Bolt retaining the skid plate to the frame: 18 ft. lbs. (24Nm)
     
    Bolt retaining the damper to the transfer case: 30 ft. lbs. (40Nm)
     
    Bolt retaining the driveshaft CV joint to the front output shaft assembly: 22 ft. lbs. (30Nm)
     
    Bolt retaining the transfer case to the extension housing: 40 ft. lbs. (54Nm)
     
    Bolt retaining the front adapter to the transfer case: 30 ft. lbs. (40Nm)
     
    Bolt retaining the transfer case to the transfer case cover: 27 ft. lbs. (36Nm)
     
    Drain plug: 18 ft. lbs. (24Nm)
     
    Fill plug: 18 ft. lbs. (24 Nm)

    Click image to see an enlarged view

    Fig. Exploded view of the 13-54 electronic shift transfer case-to-transmission mounting

     

  4.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    NOTE
    On some vehicles, when the battery cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.

  4.  
  5. Place the transmission in neutral. Raise and support the vehicle safely.
  6.  
  7. Remove or disconnect the following:

    Skid plate
     
    Damper
     
    Transfer case harness connector and position it aside
     

  8.  
  9. If transfer case disassembly is necessary, remove the drain plug and drain the fluid.
    NOTE
    Index-mark the front output shaft assembly and the front driveshaft constant velocity (CV) joint. Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight of the driveshaft can pinch the boot between the shaft and the boot can and cause the boot to tear.


    NOTE
    Index-mark the front flange on the rear driveshaft and the flange on the transfer case.


    NOTE
    Secure the transfer case to the jack with safety straps.



    Front driveshaft from the transfer case and position the driveshaft aside. Remove and discard the bolts and washers.
     



    Rear driveshaft
     

  10.  
  11. Position a high lift jack under the transfer case.
  12.  
  13. Remove or disconnect the following:

    Five bolts retaining the transfer case to the extension housing
     
    Transfer case rearward and off of the transmission output shaft
     

  14.  
  15. Remove and discard the front extension housing gasket and clean the mating surfaces.
  16.  

To install:

  1. Installation is the reverse of removal. Take note of the following:

    Install the transfer case with a new gasket.
     
    Tighten the bolts that retain the transfer case to the extension housing in a clockwise direction beginning with the upper LH bolt.
     
    Install the front and the rear driveshafts with new bolts. If new bolts are not available, coat the threads of the original bolts with Threadlock and Sealer E0AZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5.
     
    When installing the front driveshaft, always connect it to the axle first and then connect it to the transfer case.
     
    Align the index marks when installing the front and rear driveshafts.
     

  2.  
  3. Observe the following torques:

    Nut retaining the flange to the rear output shaft: 262 ft. lbs. (355 Nm)
     
    Bolt retaining the rear driveshaft to the flange: 82 ft. lbs. (111 Nm)
     
    Bolt retaining the motor assembly and connector to the transfer case cover: 89 inch lbs. (10 Nm)
     
    Bolt retaining the skid plate to the frame: 18 ft. lbs. (24 Nm)
     
    Bolt retaining the damper to the transfer case: 30 ft. lbs. (40 Nm)
     
    Bolt retaining the driveshaft CV joint to the front output shaft assembly: 22 ft. lbs. (30 Nm)
     
    Bolt retaining the transfer case to the extension housing: 40 ft. lbs. (54 Nm)
     
    Bolt retaining the front adapter to the transfer case: 30 ft. lbs. (40 Nm)
     
    Bolt retaining the transfer case to the transfer case cover: 27 ft. lbs. (36 Nm)
     
    Drain plug: 18 ft. lbs. (24 Nm)
     
    Fill plug: 18 ft. lbs. (24 Nm)
     

  4.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    NOTE
    On some vehicles, when the battery cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.

  4.  
  5. With the vehicle in NEUTRAL, raise and support the vehicle.
  6.  
  7. Remove the skid plate.
  8.  
  9. Remove the damper, if equipped.
  10.  
  11. Disconnect the transfer case harness connector and position it aside.
  12.  
  13. If transfer case disassembly is necessary, remove the drain plug and drain the fluid. Install the drain plug when all of the fluid has drained.
    NOTE
    Index-mark the front output shaft assembly and the front driveshaft constant velocity (CV) joint.


    WARNING
    Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight of the driveshaft can pinch the boot between the shaft and the boot can and cause the boot to tear.

  14.  
  15. Index-mark the front output shaft assembly and the front driveshaft constant velocity (CV) joint.
  16.  
  17. Remove and discard the bolts and washers.
  18.  
  19. Disconnect the front driveshaft from the transfer case and position the driveshaft aside.
    NOTE
    Index-mark the front flange on the rear driveshaft and the flange on the transfer case.

  20.  
  21. Remove the rear driveshaft.
    CAUTION
    Secure the transfer case to the jack with safety straps.

  22.  
  23. Position a high lift jack under the transfer case.
  24.  
  25. Remove the five bolts retaining the transfer case to the extension housing.
  26.  
  27. Slide the transfer case rearward and off of the transmission output shaft.
  28.  
  29. Remove and discard the front extension housing gasket, and clean the mating surfaces.
  30.  

To install:

  1. Install the transfer case with a new gasket.
  2.  
  3. Tighten the bolts that retain the transfer case to the extension housing in a clockwise direction beginning with the upper LH bolt. Torque to 40 ft. lbs. (54 Nm).
  4.  
  5. Install the front driveshaft with new bolts and washers and the rear driveshaft with new bolts. If new bolts are not available, coat the threads of the original bolts with Threadlock and Sealer E0AZ-19554-AA, or equivalent.
    NOTE
    When installing the front driveshaft, always connect it to the axle first and then connect it to the transfer case.


    NOTE
    Align the index marks when installing the front and rear driveshafts.

  6.  
  7. The remainder of installation is the reverse of the removal procedure.
  8.  
  9. Check and, if necessary, fill the transfer case with the specified type and quantity of fluid.
  10.  

 
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