This procedure drains and refills the transfer case fluid in a 2011-2014 Ford F-150 4WD with the 5.0L V8 Coyote engine, ensuring proper lubrication and operation of the four-wheel drive system.

Warnings

Tools required

Parts

• Transfer case drain plug washer (if damaged) × 1 — Use OEM specification
• Transfer case fill plug o-ring (if damaged) × 1 — Use OEM specification

Fluids

• Motorcraft Transfer Case Fluid — 2.5 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Allow transfer case to cool to a safe working temperature if recently driven (warm but not hot is ideal for complete drainage)
3. Raise vehicle if additional clearance is needed for access, using appropriate jack points and supporting on jack stands
4. Locate the transfer case positioned behind the transmission on the driver's side of the vehicle
5. Identify the drain plug on the bottom of the transfer case (8mm hex) and the fill plug on the passenger side of the case (3/8 inch square drive)
6. Have new fluid, drain pan, and all tools staged and ready before beginning

Procedure

1. 1

   Clean drain and fill plug areas
   Use a wire brush and shop rag to clean the area around both the drain plug (bottom of transfer case) and fill plug (passenger side of case). Remove any dirt, road grime, or debris that could contaminate the fluid or fall into the case during service.
2. 2

   Loosen fill plug first
   Using a 3/8 inch square drive ratchet or breaker bar, loosen the fill plug on the passenger side of the transfer case approximately 1-2 turns. Do NOT remove it completely yet. This ensures you can refill the case after draining. If the fill plug is seized or stripped, stop and address this issue before draining.
   ⚠Always loosen the fill plug before draining. If the fill plug cannot be removed, you will not be able to refill the transfer case after draining.
3. 3

   Position drain pan and remove drain plug
   Position the drain pan directly under the transfer case drain plug, which is located on the bottom of the case. Using an 8mm hex socket or Allen key, slowly loosen and remove the drain plug. Allow the fluid to drain completely. The transfer case holds approximately 2.5 quarts. Fluid drainage will take 10-15 minutes for complete evacuation.
   ⚠Fluid may drain with initial force. Keep hands and face clear of the drain stream. Wear safety glasses and gloves.
4. 4

   Inspect drained fluid and drain plug
   While fluid is draining, inspect the drained fluid for metal shavings, excessive debris, or abnormal discoloration. Small amounts of fine metallic particles are normal, but large chunks or excessive material may indicate internal wear. Inspect the drain plug for metal particles stuck to the magnetic portion. Clean the drain plug thoroughly with a shop rag. Inspect the drain plug washer for damage and replace if crushed, cracked, or deteriorated.
5. 5

   Install drain plug
   Once fluid has completely stopped draining, wipe the drain hole opening clean with a shop rag. Install the drain plug with washer (new or reusable if in good condition). Thread the plug in by hand first to ensure proper engagement, then tighten to specification using a torque wrench.
   ⚠Do not overtighten the drain plug as this can strip the aluminum threads in the transfer case housing, requiring costly repairs.
   Torque spec

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

   Remove fill plug completely
   Now that the drain plug is reinstalled, completely remove the fill plug from the passenger side of the transfer case using the 3/8 inch square drive ratchet. Inspect the fill plug o-ring for damage and replace if necessary. Set the fill plug aside in a clean location.
7. 7

   Fill transfer case with new fluid
   Using a fluid pump or transfer case fill bottle with appropriate nozzle, insert the fill tube into the fill plug opening. Slowly pump in Motorcraft Transfer Case Fluid until fluid begins to trickle out of the fill hole. The capacity is approximately 2.5 quarts. Fill slowly to allow air to escape and prevent overflow. Continue filling until a steady stream of clean fluid runs from the fill hole, indicating the case is completely full.
   ℹ️Only use Motorcraft Transfer Case Fluid or equivalent meeting Ford specification WSS-M2C938-A. Using incorrect fluid can cause damage to the electronic clutch system.
8. 8

   Install fill plug
   Allow excess fluid to drain back until it stops dripping from the fill hole (fluid level should be at the bottom of the fill hole threads). Wipe the fill plug and surrounding area clean. Install the fill plug with o-ring, threading it in by hand first. Tighten the fill plug to specification using a torque wrench.
   Torque spec

   Transfer Case Fill Plug25 Nm (18 lb-ft)
9. 9

   Clean up and inspect for leaks
   Wipe down the entire transfer case exterior to remove any spilled fluid. Remove the drain pan and properly dispose of used transfer case fluid according to local regulations. Inspect both the drain and fill plugs for any signs of leakage. If vehicle was raised, lower it to the ground safely.
10. 10

    Test drive and recheck
    Start the engine and allow it to reach normal operating temperature. Shift the transfer case through all range positions (2H, 4H, 4L if equipped) while stationary or at very low speed as appropriate. Drive the vehicle for 5-10 miles, using 4WD modes if safe to do so. After test drive, recheck the fill plug and drain plug areas for any signs of leakage. Check fluid level by briefly removing fill plug - fluid should be at the bottom of the fill hole threads.

Reassembly

1. Ensure both drain and fill plugs are torqued to proper specification
2. Verify no tools or materials are left under the vehicle
3. Wipe down transfer case housing to easily identify any future leaks

Verification

• Check that both drain plug and fill plug are properly torqued and show no signs of leakage
• Verify transfer case shifts smoothly through all ranges (2H, 4H, 4L)
• Test drive vehicle and confirm proper 4WD engagement and operation
• Recheck fluid level after test drive - fluid should be visible at bottom of fill plug hole when plug is removed
• Inspect drain and fill plug areas after test drive to ensure no leaks are present
• Record mileage and date of service for future maintenance tracking

More procedures for this vehicle