This procedure covers the removal and replacement of the BorgWarner electronic shift transfer case on a 2011-2014 Ford F-150 3.5L EcoBoost 4WD, including driveshaft disconnection, crossmember removal, and proper fluid refill.

Warnings

Tools required

Parts

• Transfer case (if replacing) × 1 — BorgWarner BW1356 compatible with 3.5L EcoBoost
• Transfer case output seal × 1 — Use OEM specification
• Transfer case front driveshaft seals × 1 — Use OEM specification
• Transfer case mounting bolts × 1 — Inspect and replace if damaged
• Transfer case to transmission adapter gasket × 1 — Use OEM specification

Fluids

• Motorcraft Transfer Case Fluid — 2.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable to prevent accidental engagement of electronic shift motor
3. Raise vehicle to working height and support on jack stands at frame rails - vehicle must be level
4. Remove skid plate if equipped using appropriate fasteners
5. Allow transfer case to cool completely if vehicle was recently driven

Procedure

1. 1

   Drain transfer case fluid
   Place drain pan beneath transfer case. Remove the drain plug located on the bottom of the transfer case using a 17mm socket. Allow fluid to drain completely for at least 10 minutes. Inspect drained fluid for metal particles or discoloration indicating internal damage.
2. 2

   Disconnect front driveshaft
   Using a paint marker or scribe, mark the front driveshaft flange to transfer case flange alignment. Remove the four bolts connecting the front driveshaft to the transfer case output flange using a 21mm socket. Support the driveshaft and lower it away from the transfer case. Secure driveshaft to frame with wire or strap to prevent strain on CV joints.
   ⚠Do not allow driveshaft to hang unsupported as this can damage CV joints
   Torque spec

   Driveshaft Flange Bolts20 Nm (15 lb-ft)
3. 3

   Disconnect rear driveshaft
   Mark the rear driveshaft flange to transfer case output flange alignment. Remove the four bolts connecting the rear driveshaft to the transfer case using a 21mm socket. Support and lower the driveshaft. On two-piece driveshafts, remove center bearing support bolts from crossmember if necessary for clearance.
   Torque spec

   Driveshaft Flange Bolts20 Nm (15 lb-ft)
4. 4

   Disconnect transfer case electrical connections
   Locate the transfer case shift motor connector on the driver side of the transfer case. Press the connector release tab and disconnect the electrical connector. Disconnect the speed sensor connector on the rear of the transfer case if equipped. Release any wiring harness clips from the transfer case or crossmember.
5. 5

   Disconnect vent hose
   Locate the transfer case vent hose on top of the transfer case assembly. Carefully pull the vent hose straight up and off the barb fitting. Note routing for reinstallation.
6. 6

   Support transfer case
   Position transmission jack or transfer case adapter beneath the transfer case. Raise jack until it makes contact and supports the weight of the transfer case. Secure transfer case to jack with safety straps or chains to prevent it from falling during removal.
   ⚠️Transfer case must be properly secured to jack before removing mounting hardware - failure to do so can result in severe injury
7. 7

   Remove transfer case crossmember support
   With transfer case supported, remove the four bolts securing the transfer case crossmember support to the frame rails using a 19mm socket. Carefully lower and remove the crossmember. Inspect crossmember bushings for wear and replace if deteriorated.
8. 8

   Remove transfer case mounting bolts
   Locate the six mounting bolts securing the transfer case to the transmission adapter housing. Using a T-30 Torx bit or appropriate socket, remove all six mounting bolts working in a cross pattern. Keep track of bolt locations as some may be different lengths.
   ⚠Support transfer case weight on jack during bolt removal to prevent binding
   Torque spec

   Transfer Case Bolts35 Nm (26 lb-ft)
9. 9

   Separate and lower transfer case
   With all mounting bolts removed, carefully slide the transfer case rearward away from the transmission. The transfer case input shaft will disengage from the transmission output shaft. Use pry bar if necessary but avoid damaging sealing surfaces. Once clear, slowly lower the transfer case on the jack and remove from under vehicle.
10. 10

    Inspect and prepare mating surfaces
    Inspect the transmission output shaft splines for wear or damage. Check the transfer case input shaft splines and chain condition if case is being reused. Remove old gasket material from transmission adapter housing and transfer case mating surface using a plastic scraper. Clean surfaces with brake cleaner and install new gasket on transfer case mating surface.
11. 11

    Install transfer case
    Position transfer case on transmission jack and raise into position. Align transfer case input shaft with transmission output shaft, ensuring proper engagement of splines. Carefully slide transfer case forward until mating surface contacts transmission adapter housing. Ensure gasket remains properly positioned.
    ⚠Do not force transfer case onto transmission - input shaft must align smoothly with output shaft splines
12. 12

    Install transfer case mounting bolts
    Install all six transfer case mounting bolts hand-tight, ensuring proper thread engagement. Torque bolts in a cross pattern to specification using T-30 Torx bit or appropriate socket. Verify transfer case is seated flush against transmission adapter housing.
    Torque spec

    Transfer Case Bolts35 Nm (26 lb-ft)
13. 13

    Install crossmember support
    Raise crossmember into position between frame rails. Install four mounting bolts and torque to specification. Verify transfer case is properly supported before removing transmission jack.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
14. 14

    Reconnect driveshafts
    Connect rear driveshaft to transfer case output flange, aligning marks made during removal. Install bolts and torque to specification. Connect front driveshaft to transfer case, aligning marks, and torque bolts to specification. Remove any support wires or straps from driveshafts.
    Torque spec

    Driveshaft Flange Bolts20 Nm (15 lb-ft)
15. 15

    Reconnect electrical and vent connections
    Reconnect transfer case shift motor electrical connector until it clicks into place. Reconnect speed sensor connector if equipped. Install vent hose onto transfer case barb fitting, pushing firmly until fully seated. Secure any wiring harness clips to transfer case or crossmember.
16. 16

    Fill transfer case with fluid
    Locate fill plug on rear of transfer case. Remove fill plug using 17mm socket. Using fluid pump or funnel with hose, add Motorcraft Transfer Case Fluid through fill hole until fluid reaches bottom of fill hole threads (approximately 2.5 quarts). Install and torque drain plug and fill plug to specification. Wipe area clean.
    ℹ️Vehicle must be level for accurate fluid fill - overfilling or underfilling can cause transfer case damage

Reassembly

1. Reinstall skid plate if equipped and torque fasteners to specification
2. Remove jack stands and lower vehicle to ground
3. Reconnect negative battery cable
4. Start engine and shift through all transfer case positions (2H, 4H, 4L) to verify proper operation of electronic shift motor
5. Check for fluid leaks around transfer case seals, drain plug, and fill plug after initial test drive

Verification

• Test drive vehicle and verify smooth operation in 2WD mode with no vibrations or unusual noises
• Engage 4WD High and verify proper engagement with 4x4 indicator illuminating on dash
• Test 4WD Low engagement in safe area - verify transfer case shifts properly and low range operates correctly
• After 10-15 minute test drive, recheck transfer case fluid level with vehicle level - fluid should be at bottom of fill plug hole
• Inspect all connections for fluid leaks, particularly at output shaft seals and gasket surfaces
• Verify no check engine lights or transfer case fault codes stored in vehicle computer

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