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Transfer Case Reassembly

NOTE: Before assembly, lubricate all moving parts and oil seal lips with clean Mercon ATF.
  1. Using Needle Bearing Replacer (49 UN01 024) and Driver Handle (49 F027 003) or equivalent, install front bearing into front output shaft case bore, and install snap ring. Install front output yoke-to-flange oil seal using Output Shaft Bearing Replacer (49 F027 005) or equivalent.
  2. Using a press, install ring gear into front case. Ensure serrations on outside diameter of ring gear align with serrations on inside diameter of front case. See Figure.
  3. Using Seal Installer (49 U027 003) and Drive Handle (49 F027 003) or equivalent, install NEW oil seal into the front adapter bore. Using Bearing Installer (49 UN01 025) press NEW needle bearing and sleeve into end of input shaft.
    4. NOTE: Ensure recessed face of sun gear and snap ring groove on outer bearing race face toward rear of transfer case. Stepped face of thrust washer faces toward bearing.
  4. Slide sun gear, thrust plate and thrust washer onto input shaft. Press bearing onto input shaft. See Figure. Install external snap ring to input shaft. See Figure. Install internal snap ring to front planet assembly.
  5. Position tanged snap ring in main drive gear bearing retainer groove. Place input shaft and front planet assembly in main drive gear bearing retainer. See Figure. Expand tanged snap ring while pushing inward until front planet assembly and input shaft are seated in main drive gear bearing retainer. Ensure snap ring is in place by holding main drive gear bearing retainer, and carefully tapping face of input shaft with a plastic mallet.
    6. CAUTION: Main drive gear bearing retainer must be installed within 15 minutes of application of silicone or NEW sealant must be applied. Allow one hour for silicone sealant to dry before filling transfer case with oil.
  6. Apply a bead of RTV gasket sealant on mating surface of front case. Install main drive gear bearing retainer on front case, and tighten 6 retaining bolts to specification. See TORQUE SPECIFICATIONS . Mount transfer case on holding fixture. Ensure nylon wear pads are installed on shift forks and snapped securely into place. Install High-Low (H-L) shift fork and collar as an assembly into front planet. Press oil pump drive pin into rear output shaft pinhole to previously measured height. See Figure. If oil pump drive pin height was not measured before disassembly, install drive pin to a height of 0.04" (1.0 mm).
    7. NOTE: DO NOT remove plastic insert from bore of NEW oil pump before installation. Discard plastic insert after it slides out during installation.
    NOTE: Prime oil pump through oil strainer tube with clean Mercon® ATF while turning output shaft. Ensure output shaft and oil pump rotate smoothly. If binding occurs, re-align keyway with oil pump drive pin on rear output shaft, and jiggle pump until it fully seats and pump rotates freely.
  7. Install oil pump onto rear of output shaft, with oil pump retaining arm facing toward rear of transfer case. Install oil sump magnet in slot in front case just above oil strainer. See Figure. Install front output shaft and oil pump in front case. See Figure. Install front output shaft retaining snap ring.
  8. Assemble 2WD-4WD lock-up assembly. Install large end of sleeve return spring into lock-up collar. Position lock-up hub over spring, and install lock-up hub into lock-up collar. See Figure. Press down on hub and install internal snap ring.
    9. NOTE: Driven sprocket must be installed with REAR mark facing toward rear case.
  9. Install chain, drive sprocket and driven sprocket as an assembly over output shaft. See Figure. Install driven sprocket thrust washer and snap ring.
  10. If removed, slide spring spacer on shift shaft, and position it beneath drive tang. Place torsion spring on shift shaft, and position first spring tang to left of shift shaft drive tang. Wind second spring tang clockwise past drive tang, and push torsion spring and sleeve in as far as it will go. Install helical shaft cam, and slide drive tang between torsion spring tangs as far it will go. See Fig 1.
    Fig 1: Installing Torsion Springs
    G92B12758Courtesy of FORD MOTOR CO.
    11. CAUTION: DO NOT bend helical cam when installing to front case, as damage to pin at tang end of motor shaft may occur.
  11. Install pin on tang end of shift cam into hole in front case. Position torsion spring tangs so they are pointing toward top side of transfer case, and just touching H-L shift fork. Install shift rail through H-L shift fork. Ensure shift rail is seated in front case bore.
  12. Install 2WD-4WD shift fork to 2WD-4WD lock-up assembly. Install lock-up assembly and shift fork over output shaft and onto shift rail. See Fig 2. Ensure 2WD-4WD fork roller bushing is resting on top surface of shift cam, and NOT into an inside track in cam. Lift 2WD-4WD shift fork slightly, while holding shift rail down, rotate shift cam track into H-L fork roller bushing.
    Fig 2: Installing 2WD-4WD Shift Fork Onto Shift Rail
    G99A54320Courtesy of FORD MOTOR CO.
    13. NOTE: The triangular shaft (shift rail) should be in 2WD position at final assembly.
  13. Install clutch coil housing on output shaft with cavity side or notches facing the chain cover. See Fig 3. Using Needle Bearing Replacer (49 UN01 005) and Driver Handle (49 F027 003) or equivalent, install front output shaft needle bearing into chain cover bore. Install rear output bearing and snap ring in chain cover bore.
    14. Fig 3: Identifying Output Shaft Notches
    G00386732Courtesy of MAZDA MOTORS CORP.
    CAUTION: Components must be assembled within 15 minutes of applying silicone, or NEW sealant must be applied.
  14. Apply small bead of non-acid silicone sealant to base of clutch coil studs and grommets. Install clutch coil from inside chain cover. Tighten clutch coil nuts to specification. See TORQUE SPECIFICATIONS . Ensure clutch wire is not trapped or kinked. Install lock-up return spring to shift rail and shift fork, with spring mounted in a vertical position. See Figure. Install NEW rear output yoke-to-flange seal.
    15. CAUTION: Components must be assembled within 15 minutes of applying silicone, or NEW sealant must be applied.
    NOTE: If shift shaft will not remain in 4WD High position, rotate shaft clockwise to 2WD position.
  15. Apply a continuous bead of silicone sealant to mating surface of front case. Align output shaft with chain cover output shaft bore. Align shift cam with rear case motor bore. Position rear case so spring boss engages lock-up return spring and shift rail. Install front bolts retaining case halves and tighten to specification. Install rear bolts and tighten to specification. See TORQUE SPECIFICATIONS .
  16. Apply a thin coat of silicone sealant to shift motor mounting surface and install shift motor. Rotate shift motor counterclockwise to align bolt holes, if necessary. Install shift motor mounting bolts and tighten to specification. See TORQUE SPECIFICATIONS .
  17. Install rear output shaft spacer into rear case bore. Install rear output flange, washer and NEW lock nut. See Fig 4. Tighten lock nut to specification. See TORQUE SPECIFICATIONS . Install transfer case. Fill transfer case with appropriate fluid to proper level. See LUBRICATION . Install fill plug.
    18. Fig 4: Installing Rear Output Flange, Washer & Nut
    G00386733Courtesy of MAZDA MOTORS CORP.
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