LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2006 >> Explorer 4.0 E, RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 5 (Transfer Case) >> Disassembly And Assembly >> Transfer Case - 2-Speed Torque-On-Demand >> Assembly

Transfer Case - 2-Speed Torque-On-Demand: Assembly

WARNING: This page is about a different variant/trim than selected.
    CAUTION: Do not crush the seal.
    Fig 1: Identifying Special Tool
    G04641008Courtesy of FORD MOTOR CO.
  1. Using the special tool, 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 Into Case And Special Tools
    G04641009Courtesy of FORD MOTOR CO.
  3. Using the special tool, install the oil seal.
    Fig 3: Identifying Special Tool
    G04641010Courtesy of FORD MOTOR CO.
  4. Using the special tool, install the oil seal.
    Fig 4: Identifying Special Tool
    G04641011Courtesy of FORD MOTOR CO.
  5. Install the front output shaft and flange and snap ring.
    Fig 5: Locating Snap Ring
    G04641012Courtesy of FORD MOTOR CO.
    6. CAUTION: Do not crush the bearing cage.
    Fig 6: Locating Special Tool
    G04641013Courtesy of FORD MOTOR CO.
  6. Using a suitable press and the special tool, install the bushing and the bearing, if removed.
  7. Using a suitable press, install the planetary gear carrier support bearing, if removed.
    Fig 7: Installing Planetary Gear Carrier Support Bearing
    G04641014Courtesy of FORD MOTOR CO.
  8. Install the snap ring.
    Fig 8: Locating Snap Ring
    G04641015Courtesy of FORD MOTOR CO.
  9. 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 9: Identifying Snap Ring And Front Planetary Gear Set Assembly
      G04641016Courtesy of FORD MOTOR CO.
  10. Install the shift rail.
    Fig 10: Locating Shift Rail
    G04641017Courtesy of FORD MOTOR CO.
  11. Install the reduction shift fork and the high-low collar as an assembly.
    Fig 11: Locating Reduction Shift Fork And High-Low Collar
    G04641018Courtesy of FORD MOTOR CO.
    12. CAUTION: Do not disassemble the electric shift cam assembly.
    Fig 12: Locating Electric Shift Cam Assembly
    G04641019Courtesy of FORD MOTOR CO.
  12. Install the electric shift cam assembly.
    13. CAUTION: Do not disassemble the pump assembly.
    Fig 13: Locating Rear Output Shaft
    G04641020Courtesy of FORD MOTOR CO.
  13. Install the pump assembly and the rear output shaft as an assembly.
  14. Install the thrust washer.
    Fig 14: Locating Thrust Washer
    G04641021Courtesy of FORD MOTOR CO.
  15. Install the oil pan magnet.
    Fig 15: Locating Oil Pan Magnet
    G04641022Courtesy of FORD MOTOR CO.
  16. Install the drive chain and the 2 sprockets as an assembly.
    Fig 16: Locating Drive Chain
    G04641023Courtesy of FORD MOTOR CO.
    17. 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 17: Locating Clutch Pack Assembly
    G04641024Courtesy of FORD MOTOR CO.
  17. Install the clutch pack assembly.
    18. CAUTION: Use a new snap ring.
    Fig 18: Locating Snap Ring
    G04641025Courtesy of FORD MOTOR CO.
  18. Install the snap ring.
  19. Install the wave spring.
    Fig 19: Locating Wave Spring
    G04641026Courtesy of FORD MOTOR CO.
  20. Install the apply cam and 3 steel balls.
  21. Install the cam and coil housing assembly.
    Fig 20: Locating Cam And Coil Housing Assembly
    G04641027Courtesy of FORD MOTOR CO.
  22. Install the thrust bearing.
    Fig 21: Locating Thrust Bearing
    G04641028Courtesy of FORD MOTOR CO.
  23. Using the special tools and a suitable press, install the front output shaft rear bearing into the case.
    Fig 22: Installing Front Output Shaft Rear Bearing Into Case Using Special Tools
    G04641029Courtesy of FORD MOTOR CO.
  24. Install the driven sprocket thrust washer.
    Fig 23: Locating Driven Sprocket Thrust Washer
    G04641030Courtesy of FORD MOTOR CO.
  25. Using the special tools and a suitable press, install the rear output shaft rear bearing into the case.
    Fig 24: Installing Rear Output Shaft Rear Bearing Into Case Using Special Tools
    G04641031Courtesy of FORD MOTOR CO.
  26. Position and support the clutch coil assembly, then install the 3 nuts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 25: Locating Clutch Coil Assembly Nuts
      G04641032Courtesy of FORD MOTOR CO.
    27. CAUTION: Applying excess silicone rubber can damage the internal components.
    Fig 26: Identifying Rear Case Mating Surface
    G04641033Courtesy of FORD MOTOR CO.
  27. Apply a 3 mm (0.11 in) bead of silicone rubber on the rear case mating surface.
  28. Assemble the front and rear case halves.
    Fig 27: Locating Front And Rear Case Halves
    G04641034Courtesy of FORD MOTOR CO.
  29. Install the transfer case bolts.
    • Tighten to 25 Nm (18 lb-ft) evenly in a star pattern.
      Fig 28: Locating Transfer Case Bolts
      G04641035Courtesy of FORD MOTOR CO.
  30. Install the yoke-to-flange oil seal.
    Fig 29: Identifying Special Tool
    G04641036Courtesy of FORD MOTOR CO.
  31. Install a new output flange oil seal.
    32. NOTE: Align the index marks made during disassembly.
  32. Install the output flange.
  33. Install the output shaft yoke washer.
  34. Using the special tool to hold the output flange and install the nut.
    • Tighten to 355 Nm (262 lb-ft).
      Fig 30: Identifying Special Tool
      G04641037Courtesy of FORD MOTOR CO.
    35. NOTE: Make sure the motor mounting surfaces are clean.
    Fig 31: Locating Motor Mounting Surface On Case
    G04641038Courtesy of FORD MOTOR CO.
  35. Apply a 3 mm (0.11 in) bead of sealant to the motor mounting surface on the case.
  36. Position the transfer case shift motor and install the 4 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 32: Locating Transfer Case Shift Motor Bolts
      G04641039Courtesy of FORD MOTOR CO.
  37. Install the coil wire pin to the electrical connector.
    • Install the coil wire pin (pin 16).
    • Install the connector interlock.
      Fig 33: Locating Coil Wire Pin
      G04641040Courtesy of FORD MOTOR CO.
  38. Position the heat shield and install the 3 heat shield bolts.
    • Tighten to 16 Nm (12 lb-ft).
      Fig 34: Locating Heat Shield Bolts
      G04641041Courtesy of FORD MOTOR CO.
  39. Install the transfer case in the vehicle. For additional information, refer to TRANSFER CASE .
  40. Fill the transfer case. For additional information, refer to TRANSFER CASE DRAINING AND FILLING .
scientia non olet · About LEMON Manuals