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Home >> Lincoln >> 2001 >> Navigator 5.4 R, 4WD >> Repair and Diagnosis >> Transmission >> Transfer Case >> Transfer Case - Automatic Shift >> Disassembly And Assembly >> Transfer Case >> Assembly

Transfer Case: Assembly

  1. Using a suitable press and the special tools, install the front output shaft support bearing, if removed.
    Fig 1: Installing Front Output Shaft Support Bearing
    G02138851
  2. Using the special tool, install the oil seal.
    Fig 2: Installing Oil Seal
    G02138852
  3. Install the dust shield, if removed.
    Fig 3: Installing Dust Shield
    G02138853
    4. NOTE: Support the front output shaft during installation.
    Fig 4: Installing Front Output Shaft
    G02138854
  4. Install the front output shaft.
    1. Position the front output shaft.
    2. Install the snap ring.
  5. Install the snap ring.
    Fig 5: Installing Snap Ring
    G02138855
  6. Install the ring gear, if removed.
    1. Position the ring gear.
    2. Install the snap ring.
    Fig 6: Installing Ring Gear
    G02138856
    7. CAUTION: Be careful not to crush the bearing cage.
    Fig 7: Installing Needle Bearing
    G02138857
  7. If removed, using a suitable press and the special tool, install the needle bearing into the front planet.
  8. If removed, using a suitable press, install the front planet support bearing.
    Fig 8: Installing Front Planet Support Bearing
    G02138858
  9. Install the snap ring.
    Fig 9: Installing Snap Ring
    G02138859
    10. NOTE: Rotate the front planet for correct positioning in the transfer case.
    Fig 10: Installing Front Planet
    G02138860
  10. Install the front planet.
    1. Depress the snap ring.
    2. Position the front planet.
  11. Using the special tools, install the oil seal.
    Fig 11: Installing Oil Seal
    G02138861
    12. CAUTION: Be careful not to crush the seal.
    Fig 12: Installing Shifter Shaft Seal
    G02138862
  12. Using the special tool, install the shifter shaft seal, if removed.
  13. Using a suitable press and the special tool, install the rear output shaft support bearing, if removed.
    Fig 13: Installing Rear Output Shaft Support Bearing
    G02138863
  14. Using a suitable press and the special tool, install the front output shaft rear bearing, if removed.
    Fig 14: Installing Front Output Shaft Rear Bearing
    G02138864
  15. Install the shift cam assembly.
    Fig 15: Installing Shift Cam Assembly
    G02138865
  16. Install the shift fork shaft.
    Fig 16: Installing Shift Fork Shaft
    G02138866
  17. Install the reduction shift fork assembly and the reduction hub as an assembly.
    Fig 17: Installing Reduction Shift Fork Assembly & Reduction Hub
    G02138867
  18. Install the oil pump assembly and the output shaft as an assembly.
    Fig 18: Installing Oil Pump Assembly & Output Shaft Assembly
    G02138868
  19. Install the oil pan magnet into its slot in the case.
    Fig 19: Installing Oil Pan Magnet
    G02138869
  20. Install the lockup collar and assembly and the lockup fork as an assembly.
    Fig 20: Installing Lockup Collar & Assembly & Lockup Fork
    G02138870
  21. Install the three-piece thrust bearing assembly (non-directional).
    1. Install the thrust washer.
    2. Install the thrust bearing.
    3. Install the thrust washer.
    Fig 21: Installing Three-Piece Thrust Bearing Assembly (Non-Directional)
    G02138871
  22. Install the drive chain assembly and the sprockets as an assembly.
    Fig 22: Installing Drive Chain Assembly & Sprockets
    G02138872
  23. Install the front output shaft tone wheel.
    Fig 23: Installing Front Output Shaft Tone Wheel
    G02138873
    24. CAUTION: When removing or installing the clutch assembly, do not separate the clutch pack assembly. 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 24: Installing Clutch Pack Assembly
    G02138874
  24. Install the clutch pack assembly.
  25. Install the new snap ring.
    Fig 25: Installing Snap Ring
    G02138875
  26. Install the wave spring.
    Fig 26: Installing Wave Spring
    G02138876
  27. Install the cam and the steel balls.
    1. Install the cam.
    2. Install the steel balls.
    Fig 27: Installing Cam & Steel Balls
    G02138877
  28. Install the cam/coil housing.
    Fig 28: Installing Cam/Coil Housing
    G02138878
  29. Install the thrust bearing assembly.
    1. Install the thin thrust bearing race.
    2. Install the thrust bearing.
    3. Install the thick thrust bearing race.
    Fig 29: Installing Thrust Bearing Assembly
    G02138879
  30. Install the snap ring.
    Fig 30: Installing Snap Ring
    G02138880
  31. Install the lockup shift fork spring.
    Fig 31: Installing Lockup Shift Fork Spring
    G02138881
    32. NOTE: Support the coil during installation.
    Fig 32: Installing Coil
    G02138882
  32. Install the coil if removed.
    1. Position the coil in the case.
    2. Tighten the coil nuts.
    33. CAUTION: Applying too much silicone sealant can plug the fluid filter and cause transfer case failure.
  33. Apply a small bead of silicone sealant to the transfer case mating surfaces.
    • Use Black Non-Acid Cure Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M4G273-A.
  34. Position the two transfer case halves, and tighten the bolts in the sequence shown in the illustration.
    Fig 33: Identifying Transfer Case Bolt Tightening Sequence
    G02138883
    35. NOTE: Lift up on the output shaft while installing the snap ring.
    Fig 34: Installing Snap Ring
    G02138884
  35. Install the snap ring.
  36. Install the tone wheel and the tone wheel spacer.
    Fig 35: Installing Tone Wheel & Tone Wheel Spacer
    G02138885
    37. CAUTION: Applying too much silicone sealant can plug the fluid filter and cause transfer case failure.
    Fig 36: Identifying Transfer Case & Extension Housing Mating Surfaces
    G02138886
  37. Apply a small bead of sealant to the transfer case and the extension housing mating surfaces.
    • Use Black Non-Acid Cure Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M4G273-A.
  38. Install the extension housing.
    1. Pull the wire through the extension housing.
    2. Position the extension housing.
    3. Install the bolts.
    Fig 37: Tightening Extension Housing Bolts
    G02138887
  39. Using the special tool, install the oil seal if removed.
    Fig 38: Installing Oil Seal
    G02138888
    40. CAUTION: Make sure the sensor seats flat against the boss.
    Fig 39: Installing Rear Output Shaft Speed Sensor
    G02138889
  40. Install the rear output shaft speed sensor.
    41. CAUTION: Make sure the sensor seats flat against the boss.
    Fig 40: Installing Front Output Shaft Speed Sensor
    G02138890
  41. Install the front output shaft speed sensor.
  42. Install the transfer case shift motor.
    Fig 41: Installing Transfer Case Shift Motor
    G02138891
  43. Install the front and rear output shaft speed sensor wire pins in the locations noted during their removal.
    Fig 42: Installing Front & Rear Output Shaft Speed Sensor Wire Pins
    G02138892
  44. Install the coil wire pin in the electrical connector.
    1. Install the coil wire pin.
    2. Install the wire connector spacer.
    Fig 43: Installing Coil Wire Pin
    G02138893
  45. Remove the transfer case from the special tool.
    Fig 44: Removing Transfer Case From Work Bench
    G02138894
  46. Install the transfer case in the vehicle. For additional information, refer to TRANSFER CASE  installation.
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