Transfer Case - 1-Speed Torque-On-Demand: Assembly

1.

Lubricate all internal components with the recommended transfer case lubricant during reassembly.

2.

Clean the mating surfaces of the cases.

3.

Using a press and the Output Shaft Front Bearing Installer with the Handle, install the front input shaft bearing.

Courtesy of FORD MOTOR COMPANY

4.

Using a press and the Front Axle Oil Seal Installer with the Handle, install the front shaft support bearing.

Courtesy of FORD MOTOR COMPANY

5.

Using the Input Shaft Oil Seal Installer, install a new front output shaft seal.

Courtesy of FORD MOTOR COMPANY

6.

Install the case to the Transmission Holding Fixture. Secure the case and the Transmission Holding Fixture to the work bench.

Courtesy of FORD MOTOR COMPANY

7.

Using the Input Shaft Oil Seal Installer, install a new front input shaft seal.

Courtesy of FORD MOTOR COMPANY

8.

Install the front output shaft and the snap ring.

Courtesy of FORD MOTOR COMPANY

9.

Install the input shaft.

Courtesy of FORD MOTOR COMPANY

10.

Install the output shaft.

Courtesy of FORD MOTOR COMPANY

NOTE: Make sure the oil pump finger is in the slot in the case.

11.
Install the oil pump assembly.

Courtesy of FORD MOTOR COMPANY

12.

Install the oil pan magnet into the slot in the case.

13.

Install the 3-piece thrust bearing assembly: the thrust washer, thrust bearing and thrust washer.

14.

Install the drive chain and the sprockets as an assembly.

Courtesy of FORD MOTOR COMPANY

15.

NOTE: When 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 will occur.

NOTE: If the clutch pack is disassembled, a new clutch pack must be installed and the armature transferred. Failure to install a new clutch pack can result in component failure.

Install the clutch pack assembly with the armature. Make sure to align the clutch pack with the sprocket.

Courtesy of FORD MOTOR COMPANY

16.

Install a new snap ring.

Courtesy of FORD MOTOR COMPANY

17.

Install the wave spring.

Courtesy of FORD MOTOR COMPANY

18.

Install the cam and the steel balls.

Courtesy of FORD MOTOR COMPANY

19.

Install the cam/coil housing.

Courtesy of FORD MOTOR COMPANY

20.

Install the caged thrust bearing assembly.

Courtesy of FORD MOTOR COMPANY

21.

Install the spacer.

Courtesy of FORD MOTOR COMPANY

22.

Install the snap ring.

Courtesy of FORD MOTOR COMPANY

23.

Using a press and the Mainshaft Bearing Installer, install the rear output shaft support bearing.

Courtesy of FORD MOTOR COMPANY

24.

Using a press and the Mainshaft Bearing Installer, install the front output shaft rear bearing.

Courtesy of FORD MOTOR COMPANY

NOTE: Only apply enough silicone sealant to seal the transfer case halves together.

25.
Apply a bead of silicone sealant to the transfer case mating surface. Position the 2 transfer case halves together, aligning the coil studs through the case holes. Tighten the 20 transfer case bolts evenly in a star pattern.
- Tighten to 29 Nm (21 lb-ft).

Courtesy of FORD MOTOR COMPANY

26.

Install the 3 coil washers and nuts.
- Tighten to 10 Nm (89 lb-in).

27.

Using the Input Shaft Oil Seal Installer, install the rear output shaft seal.

Courtesy of FORD MOTOR COMPANY

NOTE: After the wire is inserted into the connector, gently pull the wire back to verify the pin is locked inside the connector.

28.
Insert the coil wire pin in the electrical connector and install the inner connector retainer.

Courtesy of FORD MOTOR COMPANY

29.

Install the connector bracket and the 2 connector bracket bolts.
- Tighten to 10 Nm (89 lb-in).

Courtesy of FORD MOTOR COMPANY

30.

Install the transfer case dampener and the transfer case dampener bolts.
- Tighten to 18 Nm (159 lb-ft).

Courtesy of FORD MOTOR COMPANY

31.

Secure the transfer case to a transmission jack and remove the transfer case from the Transmission Holding Fixture.

Courtesy of FORD MOTOR COMPANY