Ford Explorer, Maintaince And Repair Manual

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Exploded view of the manual shift transfer case controls
Click to enlarge
The following procedure should be used, if a partial or incomplete engagement of the transfer case shift lever
detent is experienced or if the control assembly requires removal.
Disconnect the negative battery cable. 1.
Raise the shift boot to expose the top surface of the cam plates. 2.
Loosen the 1 large and 1 small bolt, approximately 1 turn. Move the transfer case shift lever to the
4L
position (lever down).
3.
Move the cam plate rearward until the bottom chamfered corner of the neutral lug just contacts the
forward right edge of the shift lever. 4.
Hold the cam plate in this position and torque the larger bolt first to 70−90 ft. lbs. (95−122 Nm) and
torque the smaller bolt to 31−42 ft. lbs. (42−57 Nm). 5.
Move the transfer case in cab shift lever to all shift positions to check for positive engagement. There
should be a clearance between the shift lever and the cam plate in the 2Hfront and 4Hrear (clearance
not to exceed 3.3mm) and 4Lshift positions. 6.
Install the shift boot assembly. 7.
Reconnect the negative battery cable. 8.
Except Manual Shift Models
Both of the electronic shift and the AWD model transfer cases do not require any linkage adjustments, nor are
any possible.
Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning.
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800 ADJUSTMENTS