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Home >> Ford >> 2002 >> Explorer 4.0 K, 4WD, Standard >> Repair and Diagnosis >> Transmission >> Transfer Case >> Transfer Case - Automatic Shift >> Disassembly And Assembly >> Transfer Case >> Assembly

Transfer Case: Assembly

    CAUTION: Do not crush the seal.
    Fig 1: Installing Shifter Shaft Seal
    G02168862Courtesy of FORD MOTOR CO.
  1. Using the special tools, install the shifter shaft seal.
  2. Using the special tools, press the front output shaft support bearing into the case.
    Fig 2: Pressing Front Output Shaft Support Bearing
    G02168863Courtesy of FORD MOTOR CO.
  3. Using the special tool, install the oil seal.
    Fig 3: Installing Oil Seal
    G02168864Courtesy of FORD MOTOR CO.
  4. Using the special tool, install the oil seal.
    Fig 4: Installing Oil Seal
    G02168865Courtesy of FORD MOTOR CO.
  5. Install the front output shaft and flange and snap ring.
    Fig 5: Installing Front Output Shaft And Flange And Snap Ring
    G02168866Courtesy of FORD MOTOR CO.
  6. Install the ring gear, if removed.
    1. Position the ring gear.
    2. Install the snap ring.
      Fig 6: Installing Ring Gear
      G02168867Courtesy of FORD MOTOR CO.
  7. Install the dampener snubber.
    Fig 7: Installing Dampener Snubber
    G02168868Courtesy of FORD MOTOR CO.
    8. CAUTION: Do not crush the bearing cage.
    Fig 8: Installing Bushing And Bearing
    G02168869Courtesy of FORD MOTOR CO.
  8. If removed, using a suitable press and the special tool, install the bushing and the bearing.
  9. If removed, using a suitable press, install the planetary gear carrier support bearing.
    Fig 9: Installing Planetary Gear Carrier Support Bearing
    G02168870Courtesy of FORD MOTOR CO.
  10. Install the snap ring.
    Fig 10: Installing Snap Ring
    G02168871Courtesy of FORD MOTOR CO.
  11. Install the front planetary gear set assembly.
    1. Expand the snap ring.
    2. Position the front planetary gear set assembly, and release the snap ring.
      Fig 11: Installing Front Planetary Gear Set Assembly
      G02168872Courtesy of FORD MOTOR CO.
  12. Install the shift rail.
    Fig 12: Installing Shift Rail
    G02168873Courtesy of FORD MOTOR CO.
  13. Install the reduction shift fork and the high-low collar as an assembly.
    Fig 13: Installing Reduction Shift Fork
    G02168874Courtesy of FORD MOTOR CO.
  14. Install the electric shift cam assembly.
    Fig 14: Installing Electric Shift Cam Assembly
    G02168875Courtesy of FORD MOTOR CO.
  15. Install the pump assembly and the rear output shaft as an assembly.
    Fig 15: Installing Pump Assembly And Rear Output Shaft
    G02168876Courtesy of FORD MOTOR CO.
  16. Install the thrust washer.
    Fig 16: Installing Thrust Washer
    G02168877Courtesy of FORD MOTOR CO.
  17. Install the oil pan magnet into its slot in the case.
    Fig 17: Installing Oil Pan Magnet
    G02168878Courtesy of FORD MOTOR CO.
  18. Install the drive chain and sprockets as an assembly.
    Fig 18: Installing Drive Chain And Sprockets
    G02168879Courtesy of FORD MOTOR CO.
  19. Install the tone wheel.
    Fig 19: Installing Tone Wheel
    G02168880Courtesy of FORD MOTOR CO.
    20. CAUTION: When removing or installing the clutch pack assembly, do not separate the clutch pack assembly. Keep tension on the clutch pack upon removal. Set the clutch pack assembly on the bench in the same position as it was located in the transfer case. The thrust washer in the lower clutch pack uses tabs to hold it in place. If the thrust washer is not in place, a transfer case clearance problem can occur.
    Fig 20: Installing Clutch Pack Assembly
    G02168881Courtesy of FORD MOTOR CO.
  20. Install the clutch pack assembly.
    21. CAUTION: Use a new snap ring.
    Fig 21: Installing Snap Ring
    G02168882Courtesy of FORD MOTOR CO.
  21. Install a new snap ring.
  22. Install the wave spring.
    Fig 22: Installing Wave Spring
    G02168883Courtesy of FORD MOTOR CO.
  23. Install the apply cam and balls.
    1. Install the apply cam.
    2. Install the steel balls.
      Fig 23: Installing Apply Cam And Balls
      G02168884Courtesy of FORD MOTOR CO.
  24. Install the cam and coil housing.
    Fig 24: Installing Cam And Coil Housing
    G02168885Courtesy of FORD MOTOR CO.
  25. Install the thrust bearing.
    Fig 25: Installing Thrust Bearing
    G02168886Courtesy of FORD MOTOR CO.
  26. Using the special tools, press the front output shaft rear bearing, and the rear output shaft support bearing into the case.
    Fig 26: Pressing Front Output Shaft Rear Bearing
    G02168887Courtesy of FORD MOTOR CO.
  27. Position and support the clutch coil assembly, and install the nuts.
    Fig 27: Installing Nuts
    G02168888Courtesy of FORD MOTOR CO.
    28. CAUTION: Applying too much silicone sealant can plug the fluid filter and cause transfer case failure.
    NOTE: Make sure the transfer case mating surfaces are clean.
  28. Apply a 3-mm (1/8-inch) bead of sealant to the transfer case mating surfaces.
  29. Position the transfer case halves together.
  30. Install the bolts, tighten them evenly in a star pattern.
    Fig 28: Installing Bolts
    G02168889Courtesy of FORD MOTOR CO.
  31. Install the tone wheel.
  32. Install the oil seal.
    Fig 29: Installing Special Tool
    G02168890Courtesy of FORD MOTOR CO.
    33. NOTE: Align the index-marks made during disassembly.
  33. Assemble the following components:
    1. Install the output flange.
    2. Install the oil seal.
    3. Install the output flange washer.
    4. Install the nut.
      Fig 30: Installing Output Flange And Oil Seal
      G02168891Courtesy of FORD MOTOR CO.
  34. While holding the flange with the special tool, tighten the nut.
    Fig 31: Installing Special Tool
    G02168892Courtesy of FORD MOTOR CO.
    35. CAUTION: Make sure the sensor seats flat against the boss.
    Fig 32: Installing Front Output Shaft Speed Sensor
    G02168893Courtesy of FORD MOTOR CO.
  35. Install the front output shaft speed sensor.
    36. CAUTION: Make sure the sensor seats flat against the boss.
    Fig 33: Installing Rear Output Shaft Speed Sensor
    G02168894Courtesy of FORD MOTOR CO.
  36. Install the rear output shaft speed sensor.
    37. NOTE: Make sure the motor mounting surfaces are clean.
    Fig 34: Applying Sealant To Motor Mounting Surface
    G02168895Courtesy of FORD MOTOR CO.
  37. Apply a 3-mm (1/8-inch) bead of sealant to the motor mounting surface on the case.
  38. Install the transfer case shift motor.
    Fig 35: Installing Transfer Case Shift Motor
    G02168896Courtesy of FORD MOTOR CO.
  39. Install the coil wire pin in the electrical connector.
    1. Install the coil wire pin.
    2. Install the connector interlock.
      Fig 36: Installing Coil Wire Pin In Electrical Connector
      G02168897Courtesy of FORD MOTOR CO.
  40. Install the heat shield.
  41. Install the dampener.
  42. Remove the transfer case from the special tool.
  43. Install the transfer case in the vehicle. For additional information, refer to TRANSFER CASE .
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