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Transfer Case: Assembly

WARNING: This page is about a different variant/trim than selected.
NOTE: Prior to assembly, lubricate all parts with MERCON® Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent.
  1. Using the special tools and a suitable press, install the bearing.
    Fig 1: Installing Bearing
    G03915497Courtesy of FORD MOTOR CO.
  2. Install the snap ring.
    Fig 2: Installing Snap Ring
    G03915491Courtesy of FORD MOTOR CO.
  3. Using the special tool, install the oil seal.
    Fig 3: Installing Oil Seal
    G03915499Courtesy of FORD MOTOR CO.
    4. CAUTION: Do not crush the needle bearing.
    Fig 4: Installing Needle Bearing
    G03915500Courtesy of FORD MOTOR CO.
  4. Using the special tools and a suitable press, install the needle bearing.
  5. Using the special tools and a suitable press, install the sleeve bearing.
    Fig 5: Installing Sleeve Bearing
    G03915501Courtesy of FORD MOTOR CO.
    6. NOTE: The recessed face of the sun gear must face the rear of the transfer case.
    NOTE: The indentations in the thrust plate must face upward.
    Fig 6: Installing Sun Gear Thrust Plate And Snap Ring
    G03915502Courtesy of FORD MOTOR CO.
  6. Install the sun gear, the thrust plate, and the snap ring.
    7. NOTE: The stepped face of the thrust washer must face upward.
    Fig 7: Installing Input Shaft Assembly And Thrust Washer
    G03915487Courtesy of FORD MOTOR CO.
  7. Install the input shaft assembly and the thrust washer.
    8. NOTE: Install the bearing on the input shaft assembly so that the snap ring groove in the bearing is closest to the top of the planet carrier.
    Fig 8: Installing Bearing
    G03915504Courtesy of FORD MOTOR CO.
  8. Using a suitable press, install the bearing.
  9. Install the snap ring.
    Fig 9: Installing Snap Ring
    G03915485Courtesy of FORD MOTOR CO.
  10. Using the special tool, install the oil seal.
    Fig 10: Installing Oil Seal
    G03915506Courtesy of FORD MOTOR CO.
  11. Install the large snap ring in the groove in the front adapter.
    Fig 11: Installing Large Snap Ring In Groove In Front Adapter
    G03915483Courtesy of FORD MOTOR CO.
    12. CAUTION: Install the front adapter within 15 minutes of applying the silicone sealant or it will be necessary to apply new sealant. If possible, allow one hour before filling the transfer case with lubricant to allow the silicone sealant to cure.
  12. Apply a 3-mm (1/8-inch) bead of silicone sealant to the front adapter mounting surface of the transfer case.
    • Use Ultra Silicone Sealant F7TZ-19554-AA or equivalent.
      Fig 12: Applying Bead Of Silicone Sealant To Front Adapter Mounting
      G03915508Courtesy of FORD MOTOR CO.
  13. Position the front adapter on the transfer case, and install the six bolts.
    Fig 13: Positioning Front Adapter On Transfer Case
    G03915509Courtesy of FORD MOTOR CO.
  14. Install the input shaft assembly and the complete carrier assembly as an assembly.
    • Align the pinion gears gear teeth and the ring gear teeth. Expand the snap ring and push inward on the planet carrier until the input shaft assembly seats fully in the front adapter. Verify that the snap ring engaged the assembly by holding the front adapter and lightly tapping the face of the input shaft assembly against a wooden block.
      Fig 14: Installing Input Shaft Assembly
      G03915510Courtesy of FORD MOTOR CO.
  15. Attach the front case to the special tool.
    Fig 15: Attaching Front Case To Special Tool
    G03915511Courtesy of FORD MOTOR CO.
  16. Install the new shift fork facings. Verify that they snap securely into place.
    Fig 16: Installing New Shift Fork Facings
    G03915494Courtesy of FORD MOTOR CO.
  17. Install the reduction hub and the reduction fork assembly as an assembly.
    Fig 17: Installing Reduction Hub And Reduction Fork Assembly
    G03915513Courtesy of FORD MOTOR CO.
    18. NOTE: Do not remove the plastic insert from the bore of a new pump assembly. Discard it after it slides out of the bore during the pump assembly installation on the rear output shaft.
  18. Install the pump assembly on the rear output shaft.
    • Align the keyway in the cover and the spring pin in the rear output shaft and fully seat the pump assembly on the shaft. The shaft will rotate freely in the pump assembly when the pump assembly is fully seated.
      Fig 18: Installing Pump Assembly On Rear Output Shaft
      G03915476Courtesy of FORD MOTOR CO.
  19. If the pump assembly does not turn freely, realign the keyway and the spring pin and jiggle the pump assembly until it seats fully and rotates freely on the shaft.
    Fig 19: Aligning Keyway And Spring Pin And Jiggle Pump Assembly
    G03915515Courtesy of FORD MOTOR CO.
  20. Prime the pump assembly.
    • Submerge the pump in a container full of clean MERCON® Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent.
  21. Install the rear output shaft and the pump assembly.
    Fig 20: Installing Rear Output Shaft And Pump Assembly
    G03915475Courtesy of FORD MOTOR CO.
  22. Install the oil strainer and the magnet in the slot in the case.
    Fig 21: Installing Oil Strainer And Magnet In Slot In Case
    G03915474Courtesy of FORD MOTOR CO.
  23. Install the front output shaft assembly.
    Fig 22: Installing Front Output Shaft Assembly
    G03915518Courtesy of FORD MOTOR CO.
  24. Install the snap ring.
    Fig 23: Installing Snap Ring
    G03915477Courtesy of FORD MOTOR CO.
  25. Install the drive chain, the drive sprocket, and the driven sprocket as an assembly.
    Fig 24: Installing Drive Chain Drive Sprocket
    G03915520Courtesy of FORD MOTOR CO.
  26. Install the spacer and the snap ring.
    Fig 25: Installing Spacer And Snap Ring
    G03915472Courtesy of FORD MOTOR CO.
  27. Install the shift rail through the reduction shift fork. Verify that the shift rail seats in the case bore.
    Fig 26: Installing Shift Rail Through Reduction Shift Fork
    G03915522Courtesy of FORD MOTOR CO.
  28. Slide the spacer and the torsion spring on the shift shaft and position it beneath the drive tang.
    Fig 27: Identifying Slide Spacer And Torsion Spring On Shift Shaft
    G03915523Courtesy of FORD MOTOR CO.
    29. WARNING: Keep fingers away from spring ends. Failure to follow these instructions may result in personal injury.
    Fig 28: Positioning First Spring Tang To Left Of Drive Tang
    G03915524Courtesy of FORD MOTOR CO.
  29. Position the first spring tang to the left of the drive tang.
    30. WARNING: Keep fingers away from spring ends. Failure to follow these instructions may result in personal injury.
    Fig 29: Pushing Torsion Spring And Sleeve
    G03915525Courtesy of FORD MOTOR CO.
  30. Wind the second spring tang clockwise past the drive tang, and push the torsion spring and sleeve in as far as it will go.
  31. Install the electric shift cam, and slide the drive tang between the torsion spring tangs as far as it will go.
    Fig 30: Installing Electric Shift Cam, And Slide Drive Tang
    G03915526Courtesy of FORD MOTOR CO.
    32. CAUTION: Do not bend the cam during installation. This will damage the pin on the end of the shift shaft.
    Fig 31: Installing Pin On End Of Shift Shaft Into Hole In Case
    G03915527Courtesy of FORD MOTOR CO.
  32. Install the pin on the end of the shift shaft into the hole in the case.
  33. Position the torsion spring tangs so that they point toward the top side of the case and just touch the reduction shift fork.
    Fig 32: Positioning Torsion Spring Tangs
    G03915528Courtesy of FORD MOTOR CO.
  34. Assemble the lockup assembly.
    Fig 33: Assembling Lockup Assembly
    G03915471Courtesy of FORD MOTOR CO.
  35. Press downward on the lockup hub and install the snap ring.
    Fig 34: Installing Snap Ring
    G03915470Courtesy of FORD MOTOR CO.
  36. Install the lockup fork and the lockup collar as an assembly.
    Fig 35: Installing Lockup Fork And Lockup Collar As Assembly
    G03915531Courtesy of FORD MOTOR CO.
    37. NOTE: After the lockup fork is released, verify that the cam roller is resting on the top surface of the electric shift cam and not into an inside track.
    Fig 36: Verifying Cam Roller Resting On Top Surface Of Electric Shift Cam
    G03915532Courtesy of FORD MOTOR CO.
  37. The triangular shaft will be in the two-wheel high (2H) position at final assembly.
  38. Lift upward on the lockup fork slightly while holding down on the shift rail and rotate the electric shift cam track into the cam roller by turning the shift shaft.
    Fig 37: Lifting Upward On Lockup Fork Slightly
    G03915533Courtesy of FORD MOTOR CO.
  39. Install the shift collar hub and the return spring.
    Fig 38: Installing Shift Collar Hub And Return Spring
    G03915534Courtesy of FORD MOTOR CO.
    40. CAUTION: Do not crush the needle bearing.
    Fig 39: Installing Needle Bearing
    G03915535Courtesy of FORD MOTOR CO.
  40. Using the special tools and a suitable press, install the needle bearing.
  41. Using the special tools and a suitable press, install the bearing.
    Fig 40: Installing Bearing
    G03915536Courtesy of FORD MOTOR CO.
  42. Install the snap ring that retains the bearing to the transfer case cover.
    Fig 41: Installing Snap Ring Retains Bearing To Transfer Case Cover
    G03915537Courtesy of FORD MOTOR CO.
  43. Using the special tool, install the oil seal.
    Fig 42: Installing Oil Seal
    G03915538Courtesy of FORD MOTOR CO.
    44. CAUTION: Assemble the cases within 15 minutes of applying the silicone sealant or it will be necessary to apply new sealant. If possible, allow one hour before filling the transfer case with lubricant to allow the silicone sealant to cure.
  44. Apply a 3-mm (1/8-in) bead of silicone sealant to the mating surface of the front case.
    • Use Ultra Silicone Sealant F7TZ-19554-AA or equivalent.
  45. Assemble the cases.
    • Align the output shaft, the shift shaft, and the return spring to their respective bores in the transfer case cover.
      Fig 43: Aligning Output Shaft Shift Shaft
      G03915539Courtesy of FORD MOTOR CO.
  46. Install the bolts.
    Fig 44: Installing Bolts (1 Of 2)
    G03915540Courtesy of FORD MOTOR CO.
  47. Install the bolts.
    Fig 45: Installing Bolts (2 Of 2)
    G03915541Courtesy of FORD MOTOR CO.
  48. Install the spacer on the rear output shaft.
    Fig 46: Installing Spacer On Rear Output Shaft
    G03915459Courtesy of FORD MOTOR CO.
  49. Using the special tool, install the oil seal.
    Fig 47: Installing Oil Seal
    G03915416Courtesy of FORD MOTOR CO.
  50. Install the oil seal in the flange.
    51. CAUTION: Align the index marks.
    Fig 48: Positioning Flange On Rear Output Shaft
    G03915417Courtesy of FORD MOTOR CO.
  51. Position the flange on the rear output shaft. If necessary, reseat the oil seal in the flange.
  52. Using the special tool, install the flange. Tighten the nut on the special tool to 54 Nm (40 lb-ft) to seat the flange on the shaft.
    Fig 49: Installing Flange
    G03915418Courtesy of FORD MOTOR CO.
  53. Use the special tool to prevent the flange from turning. Install the washer and the new nut.
    Fig 50: Installing Washer And New Nut
    G03915419Courtesy of FORD MOTOR CO.
  54. If the shift shaft will not stay in the 4H position, rotate the shift shaft clockwise to the 2H position. During motor assembly and connector installation, rotate the motor assembly counterclockwise until the motor assembly aligns with the mounting holes.
    Fig 51: Aligning With Mounting Holes
    G03915547Courtesy of FORD MOTOR CO.
    55. CAUTION: Install the motor assembly within 15 minutes of applying the silicone sealant or it will be necessary to apply new sealant. If possible, allow one hour before filling the transfer case with lubricant to allow the silicone sealant to cure.
  55. Apply a thin coat of silicone sealant to the base of the motor housing.
    • Use Ultra Silicone Sealant F7TZ-19554-AA or equivalent.
  56. Install the motor assembly and connector.
    Fig 52: Installing Motor Assembly And Connector (1 Of 2)
    G03975994Courtesy of FORD MOTOR CO.
    Fig 53: Installing Motor Assembly And Connector (2 Of 2)
    G03915549Courtesy of FORD MOTOR CO.
  57. Install the transfer case. For additional information, refer to TRANSFER CASE .
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