Ford 9L5Z-7A195-AB Transfer Case Assembly

Install a new gasket between the transfer case and the extension housing. Slide the transfer case onto the transmission output shaft, making sure the splines align, until the transfer case seats over the dowel pin. Install the five bolts securing the transfer case and tighten to the torque. Note: On manually controlled models, always tighten the large bolt securing the shifter to the extension housing before tightening the small bolt. Install the vent assembly so the white marking on the hose is positioned in the notch in the shift lever bracket (manual shift) or mounting bracket (electronic shift). Note: The upper end of the vent hose should be 3/4 inch above the top of the shifter on manually controlled models. Connect the rear driveshaft to the transfer case output flange. Tighten the bolts to the torque. Refill the transfer case with the proper type of lubricant.

The time and money involved in an overhaul are almost sure to exceed the cost of a rebuilt unit.