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Transfer Case: Assembly

WARNING: This page is about a different car, the 2009 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Prior to assembly, lubricate all parts with transfer case fluid. Failure to lubricate the parts may cause damage to the components.
  1. Using the Wheel Hub Bearing Cup Installer with the Handle and a suitable press, install the bearing.
    Fig 1: Locating Wheel Hub Bearing
    G06186357Courtesy of FORD MOTOR CO.
  2. Install the snap ring.
    Fig 2: Locating Snap Ring
    G06186351Courtesy of FORD MOTOR CO.
  3. Using the Drive Pinion Oil Seal Installer, install a new oil seal.
    Fig 3: Locating Oil Seal
    G06186359Courtesy of FORD MOTOR CO.
    4. NOTE: Do not damage the needle bearing when installing or component damage may occur.
    Fig 4: Installing Needle Bearing
    G06186360Courtesy of FORD MOTOR CO.
  4. Using the Input Shaft Bearing Installer with the Handle and a suitable press, install a new needle bearing.
  5. Using a suitable tool and a suitable press, install a new sleeve bearing.
    6. NOTE: The recessed face of the sun gear must face the rear of the transfer case.
    Fig 5: Locating Sun Gear, Thrust Plate And Snap Ring
    G06186361Courtesy of FORD MOTOR CO.
  6. Install the sun gear, thrust plate and the snap ring.
    7. NOTE: The stepped face of the thrust washer must face upward.
    Fig 6: Locating Input Shaft And Thrust Washer
    G06186347Courtesy of FORD MOTOR CO.
  7. Install the input shaft and the thrust washer.
    8. NOTE: Install the bearing on the input shaft so that the snap ring groove in the bearing is closest to the top of the planet carrier.
  8. Using a suitable press, install the bearing.
  9. Install the snap ring on the input shaft.
    Fig 7: Locating Snap Ring On Input Shaft
    G06186345Courtesy of FORD MOTOR CO.
  10. Using the Drive Pinion Oil Seal Installer, install a new oil seal.
    Fig 8: Installing Oil Seal
    G06186364Courtesy of FORD MOTOR CO.
  11. Install the large snap ring in the groove in the front adapter.
    Fig 9: Locating Large Snap Ring In Groove
    G06186343Courtesy of FORD MOTOR CO.
    12. NOTE: 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.
    Fig 10: Locating Bead Of Silicone Sealant To Front Adapter Mounting Surface Of Transfer Case
    G06186366Courtesy of FORD MOTOR CO.
  12. Apply a 3 mm (1/8 in) bead of silicone sealant to the front adapter mounting surface of the transfer case.
  13. Position the front adapter on the transfer case and install the 6 bolts.
    • Tighten to 34 Nm (25 lb-ft).
    Fig 11: Locating Transfer Case And Bolts
    G06186367Courtesy of FORD MOTOR CO.
  14. Install the input shaft and the complete carrier 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 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 against a wooden block.
    Fig 12: Installing Input Shaft And Complete Carrier Assembly
    G06186368Courtesy of FORD MOTOR CO.
  15. Attach the front case to the Transmission Holding Fixture.
    Fig 13: Locating Front Case To Transmission Holding Fixture
    G06186369Courtesy of FORD MOTOR CO.
  16. Install the new shift fork facings. Verify that they snap securely into place.
    Fig 14: Locating Shift Fork Facings
    G06186354Courtesy of FORD MOTOR CO.
  17. Install the reduction hub and the reduction fork as an assembly.
    Fig 15: Locating Reduction Hub And Reduction Fork Assembly
    G06186371Courtesy of FORD MOTOR CO.
    18. NOTE: The oil pump spring pin must be installed at the correct height so that the oil pump shaft rotates with the rear output shaft.
    NOTE: If a measurement was not taken during disassembly, install the pin to the correct height specification using a micrometer.
    Fig 16: Measuring Pin To Correct Height Specification Using Micrometer
    G06186336Courtesy of FORD MOTOR CO.
  18. Press the pin into the rear output shaft pin hole to the previously measured height.
    19. 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.
    NOTE: 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. If the pump assembly does not turn freely, realign the keyway and the spring pin and shake the pump assembly until it seats fully and rotates freely on the shaft.
    Fig 17: Locating Pump Assembly To Keyway In Cover And Spring Pin
    G06186335Courtesy of FORD MOTOR CO.
  19. Install the pump assembly on the rear output shaft.
  20. Prime the pump assembly.
    • Submerge the pump in a container full of clean transfer case fluid.
  21. Install the rear output shaft and the pump assembly.
    Fig 18: Locating Rear Output Shaft And Pump Assembly
    G06186334Courtesy of FORD MOTOR CO.
  22. Install the oil strainer and the magnet in the slot in the case.
    Fig 19: Locating Magnet And Oil Strainer From Slot In Transfer Case
    G06186333Courtesy of FORD MOTOR CO.
  23. Install the front output shaft.
    Fig 20: Locating Front Output Shaft
    G06186376Courtesy of FORD MOTOR CO.
  24. Install the snap ring.
    Fig 21: Locating Snap Ring
    G06186337Courtesy of FORD MOTOR CO.
  25. Install the drive chain, drive sprocket and the driven sprocket as an assembly.
    Fig 22: Locating Drive Sprocket And Driven Sprocket Assembly
    G06186378Courtesy of FORD MOTOR CO.
  26. Install the spacer and the snap ring.
    Fig 23: Locating Spacer And Snap Ring
    G06186331Courtesy 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 24: Locating Shift Rail Through Reduction Shift Fork
    G06186380Courtesy of FORD MOTOR CO.
  28. Slide the spacer and the torsion spring on the shift shaft and position it beneath the drive tang.
    Fig 25: Locating Spacer And Torsion Spring On Shift Shaft
    G06186381Courtesy of FORD MOTOR CO.
  29. WARNING: Keep fingers away from spring ends when releasing the spring. Spring ends are under tension and will unwind with force. Failure to follow this instruction may result in injured fingers.

    Position the first spring tang to the left of the drive tang.

    Fig 26: Locating First Spring Tang
    G06186382Courtesy of FORD MOTOR CO.
  30. WARNING: Keep fingers away from spring ends when releasing the spring. Spring ends are under tension and will unwind with force. Failure to follow this instruction may result in injured fingers.

    Wind the second spring tang clockwise past the drive tang, and push the torsion spring and sleeve in as far as it will go.

    Fig 27: Pushing Torsion Spring And Sleeve
    G06186383Courtesy of FORD MOTOR CO.
  31. Install the electric shift cam and slide the drive tang between the torsion spring tangs as far as it will go.
    Fig 28: Sliding Drive Tang Between Torsion Spring Tangs
    G06186384Courtesy of FORD MOTOR CO.
    32. NOTE: Do not bend the cam during installation. This will damage the locating pin on the end of the shift shaft.
    Fig 29: Locating Pin On End Of Shift Shaft In Hole
    G06186385Courtesy 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 30: Locating Torsion Spring Tangs Point Toward Top Side Of Case
    G06186386Courtesy of FORD MOTOR CO.
  34. Assemble the lockup assembly.
    Fig 31: Locating Lockup Assembly
    G06186330Courtesy of FORD MOTOR CO.
  35. Press downward on the lockup hub and install the snap ring.
    Fig 32: Locating Snap Ring
    G06186329Courtesy of FORD MOTOR CO.
  36. Install the lockup fork and the lockup collar as an assembly.
    Fig 33: Locating Lockup Fork And Lockup Collar Assembly
    G06186389Courtesy of FORD MOTOR CO.
    37. NOTE: The triangular shaft will be in the 2WD position (2H) at final assembly.
    Fig 34: Locating Cam Roller Resting On Top Surface
    G06186390Courtesy of FORD MOTOR CO.
  37. Verify that the cam roller is resting on the top surface of the electric shift cam and not into an inside track after the lockup fork is released.
  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 35: Rotating Electric Shift Cam Track Into Cam Roller
    G06186391Courtesy of FORD MOTOR CO.
  39. Install the shift collar hub and the return spring.
    Fig 36: Locating Shift Collar Hub And Return Spring
    G06186392Courtesy of FORD MOTOR CO.
    40. NOTE: Do not damage the needle bearing or damage to components may occur.
    Fig 37: Locating Needle Bearing
    G06186393Courtesy of FORD MOTOR CO.
  40. Using the Needle Bearing Installer with the Handle and a suitable press, install the needle bearing.
  41. Using the Wheel Hub Bearing Cup Installer with the Handle and a suitable press, install the bearing.
    Fig 38: Locating Wheel Hub Bearing Cup Installer
    G06186394Courtesy of FORD MOTOR CO.
  42. Install the snap ring that retains the bearing to the transfer case cover.
    Fig 39: Locating Snap Ring
    G06186395Courtesy of FORD MOTOR CO.
  43. Using the Valve Stem Oil Seal Installer, install a new oil seal.
    Fig 40: Locating Oil Seal
    G06186396Courtesy of FORD MOTOR CO.
    44. NOTE: 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.
    45. NOTE: Align the output shaft, the shift shaft and the return spring to their respective bores in the transfer case cover.
    Fig 41: Locating Output Shaft, Shift Shaft And Return Spring Respective Bores In Transfer Case Cover
    G06186397Courtesy of FORD MOTOR CO.
  45. Assemble the cases.
  46. Install the 9 transfer case cover bolts.
    • Tighten to 34 Nm (25 lb-ft).
    Fig 42: Locating Transfer Case Cover Bolts
    G06186323Courtesy of FORD MOTOR CO.
  47. Install the spacer on the rear output shaft.
    Fig 43: Locating Spacer On Rear Output Shaft
    G06186320Courtesy of FORD MOTOR CO.
  48. Using the Drive Pinion Oil Seal Installer, install a new oil seal.
    Fig 44: Installing Rear Output Shaft Seal
    G06186293Courtesy of FORD MOTOR CO.
    49. NOTE: Align the index marks made during disassembly.
    NOTE: Verify the oil seal is not on the shaft before installing the shaft.
  49. Position the flange on the rear output shaft. If necessary, reseat the oil seal in the flange.
  50. Install a new oil seal in the flange.
  51. Using the Transmission Output Shaft Flange Installer, install the flange. Tighten the nut on the Transmission Output Shaft Flange Installer to 54 Nm (40 lb-ft) to seat the flange on the shaft.
    Fig 45: Locating Flange
    G06186294Courtesy of FORD MOTOR CO.
  52. Use the Drive Pinion Flange Holding Fixture to prevent the flange from turning. Install a new washer and a new flange nut.
    • Tighten to 210 Nm (155 lb-ft).
    Fig 46: Locating Washer And Flange Nut
    G06186295Courtesy of FORD MOTOR CO.
    53. NOTE: Install the motor 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.
  53. Apply a thin coat of silicone sealant to the base of the motor housing.
    54. NOTE: If the shift shaft will not stay in the 4H position, rotate the shift shaft clockwise to the 2H position. During motor assembly installation, rotate the motor counterclockwise until the motor aligns with the mounting holes.
    Fig 47: Locating Shift Motor Bolts And Bracket Bolt
    G06183674Courtesy of FORD MOTOR CO.
  54. Position the motor assembly. Install the 3 shift motor bolts and bracket bolt.
    • Tighten to 10 Nm (89 lb-in).
  55. Install the coil wire to the shift motor electrical connector.
    1. Insert the wire into the electrical connector.
    2. Install the inner retainer into the electrical connector.
    Fig 48: Identifying Inner Retainer Into Electrical Connector
    G06186404Courtesy of FORD MOTOR CO.
  56. Install the transfer case. For additional information, refer to TRANSFER CASE .
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