This procedure covers the removal and replacement of the BorgWarner 44-05 electronic shift transfer case on a 2011-2014 Ford F-150 5.0L V8 4WD, including drivetrain disconnection, fluid drainage, and reinstallation.

Warnings

Tools required

Parts

• Transfer case output seal (front) × 1 — Use OEM specification
• Transfer case output seal (rear) × 1 — Use OEM specification
• Transfer case mounting gasket × 1 — Use OEM specification
• Drain plug seal washer × 1 — Use OEM specification

Fluids

• Motorcraft Transfer Case Fluid — 2.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Shift transfer case to 2H position
3. Disconnect negative battery terminal
4. Raise vehicle and support securely on jack stands at frame rails
5. Remove skid plate if equipped (4 bolts, 10mm or 13mm)
6. Place drain pan under transfer case drain plug

Procedure

1. 1

   Drain transfer case fluid
   Locate the drain plug on the bottom of the transfer case. Using a 10mm socket, remove the drain plug and allow fluid to drain completely into drain pan. This will take 5-10 minutes. Remove the fill plug (located on passenger side of case) to speed drainage and verify case drains completely. Inspect drained fluid for metal contamination or debris.
   ⚠Fluid may still be warm. Wear gloves to prevent burns.
2. 2

   Mark and remove front driveshaft
   Use marking pen to mark the front driveshaft flange position relative to the transfer case output flange for proper alignment during reassembly. Remove the 4 flange bolts connecting the front driveshaft to the transfer case. Support the driveshaft and slide it rearward to separate from transfer case. Secure driveshaft out of the way with wire or mechanics wire to prevent damage.
   Torque spec

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

   Mark and remove rear driveshaft
   Mark the rear driveshaft flange position relative to the transfer case rear output flange. Remove the 4 flange bolts connecting the rear driveshaft to the transfer case. Support the driveshaft and carefully lower it down, securing it out of the way. Do not allow driveshaft to hang unsupported as this can damage the slip yoke or U-joints.
   Torque spec

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

   Disconnect electrical connectors
   Locate the transfer case motor encoder connector and the shift motor connector on the rear of the transfer case. Press the release tabs and disconnect both electrical connectors. For the encoder, rotate the locking collar counterclockwise before pulling. Secure connectors away from work area to prevent damage.
   ℹ️The encoder connector has a twist-lock design. Do not force it or the connector will break.
5. 5

   Disconnect transfer case vent hose
   Locate the vent hose on top of the transfer case near the rear. Gently pull the vent hose off the transfer case barb fitting. The hose routes up toward the frame rail.
6. 6

   Support transfer case with jack
   Position the transfer case jack under the transfer case. Raise the jack until it makes contact with the case and provides slight upward pressure. Secure the transfer case to the jack using a strap or chain to prevent it from falling when the bolts are removed. Ensure the jack is centered and stable.
   ⚠️Transfer case must be securely strapped to jack before removing mounting bolts. Case can shift and fall causing serious injury.
7. 7

   Remove transfer case crossmember
   Locate the transfer case crossmember (support member that runs left to right under the transfer case). Remove the two mounting bolts securing the crossmember to the frame on each side (4 bolts total). Remove the two bolts securing the crossmember mount to the transfer case. Remove the crossmember and set aside.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
8. 8

   Remove transfer case mounting bolts
   Locate the 6 bolts securing the transfer case to the transmission. These bolts are located around the perimeter of the transfer case mounting flange. Using a 15mm socket and extension, remove all 6 bolts. Keep track of bolt locations as some may be different lengths. Support the weight of the transfer case on the jack as you remove the final bolts.
   ⚠Transfer case may shift when final bolt is removed. Ensure jack is secure and stable.
   Torque spec

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

   Separate and lower transfer case
   With all bolts removed, carefully slide the transfer case rearward away from the transmission output shaft. You may need to use a pry bar at the case-to-transmission seam (at the pry boss locations only) to break the seal. Once the input shaft clears the transmission, carefully lower the transfer case on the jack and remove from under the vehicle. Be prepared for additional fluid drainage when separating the case.
   ⚠Additional fluid may drain from transmission output shaft when case is separated. Position drain pan to catch spillage.
10. 10

    Inspect and prepare for installation
    Inspect the transmission output shaft for damage or excessive wear. Clean the transfer case mounting surface on the transmission with wire brush and clean rag. Install new transfer case mounting gasket onto transmission. Replace front and rear output seals on the new or rebuilt transfer case if not already done. Inspect splines on transfer case input shaft and apply light coat of clean ATF to splines.
11. 11

    Install transfer case
    Position the transfer case on the jack and raise into position. Align the transfer case input shaft with the transmission output shaft splines. Carefully slide the transfer case forward, ensuring the input shaft engages the transmission output shaft fully. The case should seat flush against the transmission mounting surface. If binding occurs, rotate the front and rear outputs slightly to align internal splines.
    ⚠Do not force the transfer case onto the transmission. Forced installation can damage splines or crack the case.
12. 12

    Install transfer case bolts and crossmember
    Install all 6 transfer case mounting bolts and tighten in a star pattern to specified torque. Reinstall the transfer case crossmember by first attaching it to the transfer case mount points, then to the frame rails. Torque all mounting bolts to specification. You can now lower and remove the transfer case jack.
    Torque spec

    Transfer Case Bolts35 Nm (26 lb-ft)

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

    Reconnect components
    Reconnect the vent hose to the barb fitting on top of the transfer case, ensuring it is pushed on fully. Reconnect both electrical connectors (shift motor and encoder), ensuring they click into place. For the encoder connector, align and push in, then rotate the collar clockwise to lock. Verify both connectors are fully seated.
14. 14

    Install driveshafts
    Raise the rear driveshaft into position and align the marks made during disassembly. Install the 4 flange bolts and torque to specification. Repeat the process for the front driveshaft, ensuring alignment marks match. Use thread locking compound on driveshaft bolts if specified by manufacturer.
    ⚠Misaligned driveshaft flanges will cause severe vibration. Verify alignment marks match before tightening.
    Torque spec

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

    Fill transfer case with fluid
    Install the drain plug with new seal washer and tighten securely. Using a fluid pump and the fill plug opening on the passenger side of the transfer case, add 2.5 quarts of Motorcraft Transfer Case Fluid. Fluid should reach the bottom of the fill plug hole. Install fill plug and tighten securely. Reinstall skid plate if equipped.
    ℹ️Only use Motorcraft Transfer Case Fluid. Other fluids can damage the electric shift motor and encoder.

Reassembly

1. Reconnect negative battery terminal
2. Lower vehicle from jack stands
3. Check for fluid leaks around transfer case seams and output seals
4. Verify all electrical connectors are secure and locked

Verification

• Start engine and allow to idle in Park
• Shift transfer case through all positions (2H, 4H, 4L, back to 2H) and verify smooth operation with no grinding or abnormal noises
• Check dashboard for 4WD warning lights - all should function normally during shifts and extinguish when shift is complete
• Test drive vehicle in 2H at low speed and verify no vibrations or unusual noises from transfer case area
• Test 4H operation on dry pavement at low speed (short distance only) to verify engagement
• Recheck fluid level after test drive - add fluid if necessary
• Inspect for leaks after test drive, particularly at output seals and case mating surface

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