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Transfer Case: Assembly

All vehicles 

NOTE: Lubricate all internal components with the recommended transfer case lubricant during reassembly.
  1. Remove the contamination and deposits from the transfer case housing and cover using a plastic scraper. Clean the transfer case housing and cover using a soft bristle brush to remove the contamination. Clean any remaining lip seal coating that may still be present on the housing or cover bores with a wire brush. Make sure the vent fitting and housing pockets are clean and clear. Remove the General Equipment: Spatula
    GFD497984Courtesy of FORD MOTOR COMPANY
  2. Clean the transfer case housing and cover flange sealing surfaces. Refer to: RTV Sealing Surface Cleaning and Preparation .
    GFD497985Courtesy of FORD MOTOR COMPANY

    Vehicles not equipped with a 6R100 transmission 

  3. Using the special tools, install the center support bearing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 307-344 (T95P-7H150-A) Installer, Driven Sprocket Wheel.
    GFD497986Courtesy of FORD MOTOR COMPANY

    All vehicles 

  4. Using the special tools, install the front planet carrier bearing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 308-410 Installer, Output Shaft Front Bearing.
    GFD497987Courtesy of FORD MOTOR COMPANY
  5. Using the special tools, install the front output shaft bearing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 307-626 Installer, Differential Seal.
    GFD497988Courtesy of FORD MOTOR COMPANY
  6. Using the special tools, install the front output shaft support bearing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 307-626 Installer, Differential Seal.
    GFD497989Courtesy of FORD MOTOR COMPANY
  7. Using the special tools, install the rear output shaft bearing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 308-410 Installer, Output Shaft Front Bearing.
    GFD497990Courtesy of FORD MOTOR COMPANY
  8. Using the special tools, install the shift shaft seal. Install Special Service Tool: 307-549 Installer, Shift Shaft Fluid Seal.
    GFD497991Courtesy of FORD MOTOR COMPANY
  9. Using the special tools, install the input shaft seal. Use Special Service Tool: 205-1018 Installation Tube, 308-943 Installer, Input Seal.
    GFD497992Courtesy of FORD MOTOR COMPANY
  10. Using the special tools, install the front output shaft seal. Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 308-944 Installer, Front Output Seal.
    GFD497993Courtesy of FORD MOTOR COMPANY
  11. Install the output shaft seal protector.
    GFD497976Courtesy of FORD MOTOR COMPANY
  12. NOTE: Do not let the front output shaft fall while removing the snap ring or damage to the component may occur.

    Install the output shaft and the out put shaft circlip.

    GFD497975Courtesy of FORD MOTOR COMPANY
  13. Install the ring gear and the ring gear circlip.
    GFD497974Courtesy of FORD MOTOR COMPANY
  14. Install the planet carrier and the front planet carrier thrust bearing.
    GFD497973Courtesy of FORD MOTOR COMPANY
  15. Install the electric shift cam assembly.
    GFD497972Courtesy of FORD MOTOR COMPANY
  16. Install the reduction hub.
    GFD497971Courtesy of FORD MOTOR COMPANY
  17. Install the output shaft.
    GFD497970Courtesy of FORD MOTOR COMPANY
  18. Install the shift fork.
    GFD497969Courtesy of FORD MOTOR COMPANY
  19. Install the shift rail.
    GFD497968Courtesy of FORD MOTOR COMPANY
  20. Install the magnet and oil pump assembly.
    GFD497967Courtesy of FORD MOTOR COMPANY

    Vehicles not equipped with a 6R100 transmission 

  21. Install the center bearing support assembly.
    GFD497966Courtesy of FORD MOTOR COMPANY

    Vehicles equipped with a 6R100 transmission 

  22. Vehicles equipped with a 6R100 transmission Install the center support assembly.
    GFD497965Courtesy of FORD MOTOR COMPANY

    All vehicles 

  23. NOTE: Install the drive chain and sprockets as an assembly.

    Install the drive chain and sprockets.

    GFD497964Courtesy of FORD MOTOR COMPANY
  24. Assemble the lockup hub assembly.
    GFD497963Courtesy of FORD MOTOR COMPANY
  25. Install the lock up hub assembly, shift fork and shift fork spring.
    GFD497962Courtesy of FORD MOTOR COMPANY
  26. Install the field coil housing.
    GFD497961Courtesy of FORD MOTOR COMPANY
  27. Install the field coil housing snap ring.
    GFD497960Courtesy of FORD MOTOR COMPANY
  28. Install the transfer case field coil.
    GFD497959Courtesy of FORD MOTOR COMPANY
  29. NOTE: Only apply enough silicone sealant to seal the transfer case halves together and does not squeeze into the transfer case.

    Apply a small bead of silicone sealant to the mating surface of the case half.

    Material: Motorcraft® Ultra Silicone Sealant / TA-29

    GFD497994Courtesy of FORD MOTOR COMPANY
  30. NOTE: Position the field coil bolts to align with the field coil bolt holes in the rear case. Position field coil wire through the field coil wire through hole in the case.

    Position the transfer case halves and tighten the bolts in the sequence shown.

    Torque: 23 lb.ft (31 Nm)

    Fig 1: Transfer Case Bolt Tightening Sequence
    GFD497995Courtesy of FORD MOTOR COMPANY
  31. Install the transfer case field coil nuts.

    Torque: 89 lb.in (10 Nm)

    GFD497956Courtesy of FORD MOTOR COMPANY
  32. Install the transfer case rear seal. Refer to: Transfer Case Rear Seal - Vehicles With: Flanged Yoke . Refer to: Transfer Case Rear Seal - Vehicles With: Slip Yoke .
  33. Clean the transfer case shift motor mating surface.
    GFD497923Courtesy of FORD MOTOR COMPANY
  34. Apply a small bead of silicone sealant to the transfer case shift motor mating surface.

    Material: Motorcraft® Ultra Silicone Sealant / TA-29

    GFD497924Courtesy of FORD MOTOR COMPANY
  35. NOTE: When installing the shift motor, tighten the bracket nuts last. Failure to follow the steps in the correct order may result in damage to the component.

    1. Install the transfer case shift motor.
    2. Install the transfer case shift motor bolts.

      Torque: 89 lb.in (10 Nm)

    3. Install the transfer case shift motor bracket bolt.

      Torque: 89 lb.in (10 Nm)

    4. Tighten the transfer case shift motor bracket nuts.

      Torque: 27 lb.in (3 Nm)

    GFD497925Courtesy of FORD MOTOR COMPANY
  36. NOTE: After the coil wire is inserted into the connector, gently pull the wire back to verify the pin is locked inside the connector.

    Install the coil wire pin in the electrical connector.

    1. Insert the coil wire pin in the electrical connector.
    2. Install the inner connector retainer.

    GFD497926Courtesy of FORD MOTOR COMPANY
  37. Remove the transfer case from the transmission adjustable mounting arms. Use the General Equipment: Adjustable Mounting Arm
GFD497955Courtesy of FORD MOTOR COMPANY
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