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Home >> Ford >> 1995 >> Explorer 4D Utility, 4WD, Standard >> Repair and Diagnosis >> Transmission >> Transfer Case >> Diagnosis & Overhaul - Borg-WARNER 1354 & 4405 Transfer Case >> Overhaul >> Transfer Case Model 1354 >> Reassembly

Transfer Case Model 1354: Reassembly

  1. Before assembly, lubricate all parts with ATF. Drive in output bore bearing and install snap ring retainer. Install front output oil seal.
  2. Using a press, install ring gear into front case with piloted chamfered end first. Align serrations on outside diameter of ring gear to serrations on inside diameter of front case and seat fully.
  3. On manual shift models, install compression spring and detent plunger into bore from inside of front case. Install a NEW "O" ring in second groove of shift shaft. Use care not to cut "O" ring during installation.
  4. Coat shift shaft with lubricant. Install shift cam, shift shaft and snap ring. Position shift shaft into 4WD high detent position. Place assist spring roller into port position on 90 degree bent tang of assist spring and insert into assist spring-roller slot of shift cam. Position assist spring into groove in front case and push to lock upper end of spring behind front case spring anchor tab. See Fig 1 . Ensure shift shaft operates freely.
    Fig 1: Installing Assist Spring On Manual Shift Models
    G92C12767Courtesy of FORD MOTOR CO.
  5. Install 2 Torx head set screws in front case and in shift cam. Torque screws to specification. On all models slide sun gear, thrust plate and thrust washer onto input shaft. Press on bearing and install snap ring onto input shaft. See Figure or Figure .
    NOTE: Sun gear recessed face and snap ring groove on bearing race should be toward rear of transfer case. Stepped face of thrust washer should face towards bearing.
  6. Install planetary gear set to sun gear and input shaft assembly. Install snap ring to planetary carrier. Install oil seal into main drive gear bearing retainer bore.
  7. Place tanged snap ring in main drive gear bearing retainer groove. Install input shaft and planetary gear set in main drive gear bearing retainer and expand tanged snap ring while pushing inward until planetary assembly and input shaft assembly are seated. Snap ring will snap into groove.
  8. Apply a bead of RTV gasket sealant on surface of front case. Position main drive gear bearing retainer on front case and install bolts. Tighten to specification. See TORQUE SPECIFICATIONS  .
  9. Install reduction shift fork and shift collar on shift shaft together into planetary assembly. Install nylon wear pads onto shift fork. Ensure dots on pads are installed in fork holes.
  10. If removed, press pin into rear output shaft. Ensure pin is installed at same protrusion height as when removed or a minimum height of .040" (1.0 mm). Install oil pump on rear output shaft with retaining arm of pump towards rear of case. Ensure pump turns freely.
  11. On manual shift models install shift rail through high-low fork and ensure shift rail is seated in bore in front case. Using shift lever, position high-low shift fork in 4H position.
    NOTE: Prime pump through oil filter pick-up tube while turning output shaft. Output shaft must turn freely within oil pump. If binding occurs, re-align cover keyway to pin of rear output shaft and jiggle pump until it fully seats and rotates freely.
  12. Inspect oil pump outside surfaces and bore for discoloration. Replace assembly if discolored. Align keyways and bores of housing, gear and cover and slide pump onto rear output shaft pin with retaining arm of cover toward rear of case. See Fig 2 .
    Fig 2: Exploded View Of Oil Pump Assembly
    G94A39180Courtesy of FORD MOTOR CO.
  13. Install output shaft and oil pump assembly in input shaft. Ensure splines of output shaft engage splines of high-low shift collar, and oil pump retainer and oil filter leg are in groove and notch of front case.
  14. Install collector magnet and front output shaft into front case. Install chain, drive sprocket and driven sprocket as an assembly over shafts. See Figure .
    NOTE: Driven sprocket must be installed with REAR mark facing toward rear cover.
  15. Install thrust washer and new snap ring on front output shaft to retain driven sprocket.
  16. Assemble 2WD/4WD lock-up assembly. Install spring in lock-up collar, place lock-up hub over spring and engage hub in notches in collar. Retain hub in collar with an internal snap ring. See Fig 3 .
  17. On electronic shift models, assemble spring spacer on camshaft. Slide spring spacer and spring onto camshaft. Position first spring tang to left side of drive tang. Wind second spring tang back to right side of drive tang. Slide spring and spacer in as far as possible. Install helical cam onto camshaft with cam tang in between spring tangs. See Fig 4 .
    Fig 3: Exploded View Of 2WD/4WD Lock-Up Assembly
    G92A12757Courtesy of FORD MOTOR CO.
    Fig 4: Installing Torsion Springs
    G92B12758Courtesy of FORD MOTOR CO.
  18. Install tang end of camshaft assembly over alignment pin in front case. Camshaft assembly tangs should point toward top of case and rest on high-low shift fork assembly.
  19. Lift 2WD/4WD shift fork slightly while holding shift rail down. Rotate helical cam track into high-low and 2WD/4WD fork roller bushings by turning helical camshaft assembly.
    NOTE: The triangular shaft should be in 2H position at final assembly.
  20. If disassembled, assemble shift collar hub to clutch housing. Install snap ring. Install clutch housing assembly on output shaft.
  21. Install NEW "O" rings on clutch coil assembly studs and grommet. Install clutch coil assembly from inside rear cover until wire and studs extend through cover. Ensure clutch coil wire exits case and is not pinched. See Fig 5 .
    Fig 5: Locating Electric Shift Clutch Coil
    G92C12759Courtesy of FORD MOTOR CO.
  22. Install 2WD/4WD shift fork and lock-up assembly over output shaft and onto shift rail. Install shift collar hub on to output shaft. Drive caged needle bearing into rear cover bore, and bearing into rear cover bore. Secure bearing with internal snap ring.
  23. Place transfer case shift shaft into 4H detent position. Coat mating surface of front case with a bead of Silicone rubber (Non-acid type). Install 2WD-4WD shift fork spring to shift rail and fork.
  24. Align output shaft with bore. Align helical camshaft assembly with bore (electronic shift). Position rear cover so that spring boss engages 2WD/4WD shift fork spring and shift rail. Install 9 bolts (starting with bolts on rear cover) and tighten to specification. See TORQUE SPECIFICATIONS  .
    NOTE: If rear cover assembly does not seat properly, move rear cover up and down slightly to permit end of shift rail to enter shift rail hole in rear cover boss, or tap rear output shaft with a sharp blow using a rubber mallet in a direction away from front output shaft while pushing down on rear cover.
  25. On electronic shift models, install speed sensor and retaining bracket. Reinstall wires into connector. Install locking sleeve into connector. If removed, install wire harness bracket on rear cover. Install speedometer drive gear and oil seal in rear cover bore.
  26. On all models, install front and rear output flange, rubber seal, flat washer and output flange lock nut. Tighten to specification. Install 4WD indicator switch with Teflon tape and torque to specification. Install drain plug and tighten to specification. Fill case with ATF and install fill plug. Tighten to specification.
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