This procedure drains and refills the transfer case fluid in a 2011-2014 Ford F-150 3.5L EcoBoost 4WD to maintain proper lubrication and extend transfer case life.

Warnings

Tools required

Parts

• Transfer case drain plug washer × 1 — Use OEM specification or copper crush washer
• Transfer case fill plug washer × 1 — Use OEM specification or copper crush washer

Fluids

• Motorcraft Transfer Case Fluid — 2.5 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. If vehicle was recently driven, allow transfer case to cool for at least 30 minutes
4. Gather all tools, parts, and fluids before starting
5. Raise front of vehicle using floor jack at designated lift points
6. Secure vehicle on jack stands at manufacturer-specified support points
7. Verify vehicle is stable before working underneath

Procedure

1. 1

   Locate transfer case and identify plugs
   Position yourself under the vehicle near the transmission. The BorgWarner 13-54 transfer case is located behind the transmission on the driver side. Identify the drain plug (lower) and fill plug (upper) on the rear face of the transfer case. Both use 8mm hex sockets. Clean the area around both plugs with a wire brush and shop rag to prevent contamination.
2. 2

   Remove fill plug first
   Using the 8mm hex socket, loosen and remove the upper fill plug. This ensures the fill plug is not seized before draining the fluid. If the fill plug cannot be removed, do not proceed with draining. Inspect the fill plug washer for damage and replace if crushed or torn.
   ⚠Always remove the fill plug before the drain plug. If the fill plug is seized and you drain the case first, you will be unable to refill it.
3. 3

   Position drain pan and remove drain plug
   Place the drain pan directly under the transfer case drain plug. Using the 8mm hex socket, slowly loosen the drain plug. Once loose, quickly remove it by hand and allow fluid to drain completely. This may take 5-10 minutes. Inspect the drain plug washer and magnet (if equipped) for metal particles, which indicate internal wear.
4. 4

   Clean and inspect plugs
   While fluid drains, clean both drain and fill plugs with shop rags. Inspect threads for damage. If the drain plug has a magnetic tip, clean off any metal particles and note the amount. Small amounts of fine metal powder are normal; large chunks or excessive material indicate potential transfer case problems. Replace both plug washers with new ones.
5. 5

   Reinstall drain plug
   Once fluid has completely stopped draining, wipe the drain plug hole area clean with a shop rag. Install the new drain plug washer onto the drain plug. Thread the drain plug in by hand to avoid cross-threading, then tighten to specification using a torque wrench.
   Torque spec

   Transfer Case Drain Plug25 Nm (18 lb-ft)
6. 6

   Fill transfer case with new fluid
   Using a fluid transfer pump or bottle with long nozzle, insert the nozzle into the fill plug hole. Slowly pump in Motorcraft Transfer Case Fluid. The capacity is approximately 2.5 quarts. Fill until fluid begins to run out of the fill hole, indicating the case is full to the proper level. Allow excess to drain for 30 seconds.
   ⚠Do not overfill. Filling until fluid runs out of the fill hole ensures correct level.
7. 7

   Reinstall fill plug
   Wipe the fill plug hole area clean. Install the new fill plug washer onto the fill plug. Thread the fill plug in by hand, then tighten to specification using a torque wrench. Wipe away any spilled fluid from the transfer case exterior.
   Torque spec

   Transfer Case Fill Plug25 Nm (18 lb-ft)
8. 8

   Lower vehicle and verify
   Carefully lower the vehicle from jack stands using the floor jack. Remove jack stands and lower completely to the ground. Start the engine and shift through all gear ranges (2H, 4H, 4L if applicable) while stationary to circulate new fluid. Check under the vehicle for leaks at both drain and fill plugs.

Reassembly

1. Ensure both drain and fill plugs are torqued to specification with new washers installed
2. Wipe down transfer case exterior to identify any future leaks
3. Remove jack stands and lower vehicle completely to ground
4. Dispose of used transfer case fluid at an approved recycling facility

Verification

• Start engine and shift transfer case through all available ranges (2H, 4H, 4L) to verify operation
• Check for leaks at drain and fill plug locations with engine running
• Test drive vehicle in 2WD and 4WD modes to ensure smooth transfer case operation without binding or noise
• Recheck plug areas for leaks after test drive
• Verify no warning lights are illuminated on instrument cluster

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