Ford AV6Z-7137-A Gear - Countershaft 3rd Speed

Removal: 1. Park vehicle on level ground, chock wheels, engage parking brake, wear eye protection and gloves. 2. Raise and securely support the vehicle with jack stands where needed to access the driveline and transfer case area. 3. Allow drivetrain to cool if hot and place drip pans under the unit to catch fluid. 4. Disconnect the negative battery cable and isolate the battery before touching any electrical connectors. 5. Label and disconnect any electrical connectors, sensors, and vacuum lines attached to the transfer case or nearby components. 6. Support the transmission/transfer case assembly with a suitable jack or support before removing any mount hardware. 7. Remove or unbolt driveline components that connect to the transfer case (examples: front/rear driveshaft, half-shafts, shift linkage), noting that specific fasteners and locations vary by design. 8. Remove mount fasteners and any brackets securing the transfer case; carefully lower the unit while supporting its weight-do not rely on the jack alone. 9. Inspect mating surfaces and surrounding components for damage and note any seals, gaskets, or clips that will need replacement. 10. Drain remaining transfer case fluid into an approved container and dispose of it according to local regulations. Installation: 1. Clean mating surfaces thoroughly and install new seals/gaskets as required; ensure replacement parts match the original design. 2. Support the transfer case on the jack and position it into place, aligning it carefully to avoid damaging input/output splines; alignment methods may vary by design. 3. Install mount fasteners and brackets loosely at first to allow final positioning, then snug progressively (follow manufacturer tightening sequence and specs from a service manual). 4. Reconnect driveline components (driveshafts, axles, linkages), ensuring proper seating and any alignment marks are matched where applicable. 5. Reconnect electrical connectors, sensors, and vacuum lines to their original locations and ensure clips/retainers are secure. 6. Reconnect the negative battery cable. 7. Refill the transfer case with the correct fluid type and amount per manufacturer instructions and check for leaks. 8. Lower the vehicle, start the engine, and cycle through gears (or run at idle) to allow fluid circulation and to verify there are no warning lights or abnormal noises. 9. Perform a short, careful road test to confirm proper operation of the drivetrain and recheck for leaks and fastener security after the test. Repair tip: 1. Replace any crush washers, drain/fill plug gaskets, and fasteners that are single-use; always inspect bearings and seals while the unit is out and replace questionable components to avoid rework.