Replace the transfer case chain on a 2011-2014 Ford F-150 5.0L V8 4WD by removing the transfer case from the vehicle, disassembling it, replacing the chain, and reinstalling.

Warnings

Tools required

Parts

• Transfer case chain × 1 — BW 4406 chain, verify part compatibility
• Transfer case gasket/seal kit × 1 — Use OEM specification
• Motorcraft transfer case fluid × 3 — XT-10-QLVC or equivalent
• RTV silicone sealant × 1 — Motorcraft TA-357 or equivalent
• Thread locker (medium strength) × 1 — Loctite 242 or equivalent

Fluids

• Motorcraft Transfer Case Fluid — 2.5 qt

Preparation

1. Park vehicle on level surface and set parking brake firmly
2. Allow engine and exhaust system to cool completely (minimum 2 hours)
3. Disconnect negative battery cable
4. Raise vehicle and support securely on jack stands at all four corners, providing adequate working clearance underneath
5. Remove skid plates or belly pans if equipped to access transfer case
6. Place drain pan under transfer case and remove drain plug to drain fluid completely
7. Clean exterior of transfer case thoroughly to prevent contamination during disassembly

Procedure

1. 1

   Remove front and rear driveshafts
   Mark the driveshaft flanges and transfer case output flanges with paint or punch marks for proper alignment during reinstallation. Remove the four bolts securing the front driveshaft to the transfer case front output flange. Support the driveshaft and remove the rear bolts or straps securing it to the front differential. Remove the driveshaft. Repeat process for rear driveshaft, disconnecting it from the transfer case rear output flange and rear differential.
   Torque spec

   Driveshaft U-Joint Straps20 Nm (15 lb-ft)
2. 2

   Disconnect electrical connectors and linkages
   Disconnect the 4WD mode selector electrical connector from the transfer case motor/encoder. If equipped with manual shift, disconnect the shift linkage by removing the retaining clip and sliding the linkage rod off the lever. Label all connectors and linkage positions for correct reassembly.
3. 3

   Disconnect transfer case vent hose
   Locate the vent hose on top of the transfer case. Squeeze the retaining clip and pull the hose off the vent fitting. Secure the hose up and away from the work area to prevent damage.
4. 4

   Support and remove transfer case
   Position transmission jack or transfer case adapter under the transfer case and secure with safety chain or strap. Remove the six mounting bolts securing the transfer case to the transmission adapter. Carefully slide the transfer case rearward to disengage the input shaft from the transmission output shaft. Lower the transfer case slowly and remove from under vehicle. Transport to clean work area and mount securely in holding fixture or bench vise.
   ⚠Transfer case may not separate easily from transmission. Use gentle prying with plastic pry tool if needed, never force or strike with metal tools.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
5. 5

   Disassemble transfer case front half
   With transfer case secured in fixture, remove all case bolts around the perimeter. Note bolt locations as they may be different lengths. Carefully separate the case halves using plastic pry points. Remove the front case half and set aside on clean surface. Do not pry between machined sealing surfaces.
   ℹ️Take photos during disassembly to document component positions and orientation for reassembly reference.
6. 6

   Remove shift mechanism and mode components
   Remove the shift fork retaining bolts and remove shift fork assembly. Remove the mode collar and shift hub from the mainshaft. Remove the mode indicator switch or encoder motor by removing retaining screws. Keep all components organized and clean.
7. 7

   Remove chain and sprockets
   Lift the drive chain off both sprockets. Remove the mainshaft snap ring using snap ring pliers. Remove the driven sprocket from the mainshaft, noting the orientation and any shims or thrust washers. Remove the drive sprocket snap ring and remove sprocket from the input shaft. Inspect both sprockets for wear, scoring, or damage. Replace if worn.
8. 8

   Clean and inspect all components
   Thoroughly clean all removed components with parts cleaner and inspect for wear or damage. Inspect case halves for cracks, stripped threads, or damage to sealing surfaces. Check all bearings for roughness or play by rotating by hand. Inspect shafts for scoring or wear. Replace any damaged or excessively worn components. Clean all RTV residue from case sealing surfaces using scraper, taking care not to gouge aluminum.
9. 9

   Install new chain and sprockets
   Install the drive sprocket onto the input shaft with proper orientation (reference photos from disassembly). Install new snap ring ensuring it seats fully in the groove. Install driven sprocket onto mainshaft with any shims or thrust washers in correct position. Install mainshaft snap ring. Route new transfer case chain around both sprockets, ensuring proper engagement. Verify chain has appropriate slack (approximately 1/4 to 1/2 inch deflection when pressed at midpoint between sprockets).
   ℹ️New chains may be slightly tighter than worn chains. Verify proper chain length and part number compatibility before installation.
10. 10

    Reinstall shift mechanism and mode components
    Install the shift hub and mode collar onto the mainshaft in correct orientation. Install the shift fork assembly and secure with bolts, applying medium-strength thread locker. Verify the shift fork engages properly with the mode collar and moves smoothly. Install the mode indicator switch or encoder motor with new O-ring if equipped.
11. 11

    Reassemble transfer case halves
    Apply thin bead of RTV silicone sealant to the rear case half sealing surface following the gasket pattern. If using gasket, install new gasket without additional RTV unless specified. Carefully align and install the front case half, ensuring all internal components remain properly positioned. Install all case bolts in correct locations and tighten in a cross-pattern sequence to ensure even clamping. Torque case bolts to specification (typically 30-40 Nm, follow specific transfer case rebuild specifications). Allow RTV to cure per manufacturer instructions before filling with fluid.
    Torque spec

    Cover Screws14 Nm (10 lb-ft)
12. 12

    Reinstall transfer case to vehicle
    Transport reassembled transfer case to vehicle. Position on transmission jack and raise into position. Align the input shaft splines with the transmission output shaft. Slide transfer case forward until it seats fully against the transmission adapter. Install all six mounting bolts and tighten to specification in a cross pattern.
    ⚠Do not force transfer case onto transmission. Rotate transfer case input shaft slightly while applying gentle forward pressure to align splines.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
13. 13

    Reconnect all connections and install driveshafts
    Reconnect the vent hose to the transfer case vent fitting. Reconnect the 4WD mode selector electrical connector. Reconnect shift linkage if equipped with manual shift. Install rear driveshaft first, aligning marks made during removal. Install front driveshaft, again aligning reference marks. Tighten all driveshaft bolts or strap fasteners to specification in a cross pattern.
    Torque spec

    Driveshaft U-Joint Straps20 Nm (15 lb-ft)
14. 14

    Fill transfer case with fluid
    Ensure drain plug is installed and torqued properly. Locate the fill plug on the side of the transfer case. Using fluid pump, add 2.5 quarts of Motorcraft Transfer Case Fluid through the fill hole until fluid begins to seep from the fill hole. Install fill plug and torque to specification. Wipe any spilled fluid from case exterior.
15. 15

    Final installation and system check
    Reinstall skid plates or belly pans if removed. Lower vehicle from jack stands. Reconnect negative battery cable. Start engine and cycle through all 4WD modes (2H, 4H, 4L if equipped) several times to verify proper operation. Check for leaks around transfer case seams, drain plug, and fill plug. Road test vehicle in all 4WD modes to verify proper engagement and no abnormal noises.
    ℹ️Some 4WD systems require vehicle to be moving at specific speeds to engage certain modes. Refer to owner's manual for proper engagement procedures.

Reassembly

1. Reassembly is included in the main procedure steps, following steps 9-15
2. Ensure all fasteners are torqued to specification in the proper sequence
3. Use new seals, gaskets, and O-rings from transfer case seal kit
4. Apply medium-strength thread locker to shift mechanism bolts and mode switch screws

Verification

• Start engine and verify no warning lights on dash related to 4WD system
• Cycle through all transfer case modes (2H, 4H, 4L) and verify engagement indicators work properly
• Test drive vehicle at low speed in 4H mode, verify smooth operation with no binding or vibration
• If equipped, verify 4L engages properly and provides proper gear reduction
• Check for fluid leaks around transfer case after test drive, particularly at case seam and fill/drain plugs
• Listen for abnormal chain noise during acceleration and deceleration in 4WD modes
• Verify proper driveshaft operation with no vibration at highway speeds in 2H mode

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