Transfer Case - Mechanical Shift: Assembly

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Install a new support O-ring seal.

Fig 1: Locating Support O-Ring Seal
Courtesy of FORD MOTOR CO.

NOTE: Prior to installation, coat the threads with thread sealant.

Using the special tool, install the sector shaft support.
- Tighten to 31 Nm (23 lb-ft).
  
  Fig 2: Using Special Tool On Sector Shaft Support
  Courtesy of FORD MOTOR CO.
Install the sector assembly.

Fig 3: Locating Sector Assembly
Courtesy of FORD MOTOR CO.
Install the spacer, the lever, the washer and the locknut.

Fig 4: Locating Washer And Locknut
Courtesy of FORD MOTOR CO.

NOTE: If installing a new poppet spring, it must be like in color to the original poppet spring.

Fig 5: Locating Poppet Screw, Spring And Poppet

G04650937

Courtesy of FORD MOTOR CO.

Assemble the poppet screw, the spring and the poppet.
Install the poppet assembly.
- Tighten to 20 Nm (15 lb-ft).
  
  Fig 6: Locating Poppet Assembly
  Courtesy of FORD MOTOR CO.
Install the rear input gear thrust washer.

Fig 7: Locating Rear Input Gear Thrust Washer
Courtesy of FORD MOTOR CO.
Install the front input gear thrust washer.

Fig 8: Locating Front Input Gear Thrust Washer
Courtesy of FORD MOTOR CO.

NOTE: Install the lock plate with the stamped letter E facing outward.

Fig 9: Locating Lock Plate

G04650941

Courtesy of FORD MOTOR CO.

Install the lock plate.
Place the input gear into the planetary carrier assembly.

Fig 10: Locating Input Gear Into Planetary Carrier Assembly
Courtesy of FORD MOTOR CO.
Install a new lock plate retaining ring.

Fig 11: Locating Lock Plate Retaining Ring
Courtesy of FORD MOTOR CO.
Using the special tools and a suitable press, install a new front input bearing.

Fig 12: Using Special Tool On Front Input Bearing
Courtesy of FORD MOTOR CO.
Install a new bearing retainer ring.

Fig 13: Locating Bearing Retainer Ring
Courtesy of FORD MOTOR CO.
Position the planetary assembly into the front case.

Fig 14: Locating Planetary Assembly Into Front Case
Courtesy of FORD MOTOR CO.
Install a new retaining ring.
1. Install the special tool.
2. Install a new retaining ring.
  - Remove the special tool.
    
    Fig 15: Using Special Tool On Retaining Ring
    Courtesy of FORD MOTOR CO.
Using the special tools, install a new input seal.

Fig 16: Using Special Tool On Input Shaft
Courtesy of FORD MOTOR CO.
Using the special tools and a suitable press, install a new front output ball bearing.

Fig 17: Installing Front Output Ball Bearing
Courtesy of FORD MOTOR CO.
Install a new front output ball bearing retaining ring.

Fig 18: Locating Front Output Ball Bearing Retaining Ring
Courtesy of FORD MOTOR CO.
Position the front output shaft in the front case.

Fig 19: Locating Front Output Shaft In Front Case
Courtesy of FORD MOTOR CO.
Install a new retaining ring.
1. Install the special tool.
2. Install a new retaining ring.
  - Remove the special tool.
    
    Fig 20: Using Special Tool On Retaining Ring
    Courtesy of FORD MOTOR CO.
Using the special tools, install a new front output seal.

Fig 21: Installing Front Output Seal
Courtesy of FORD MOTOR CO.
Using the special tools, install a new slinger on the front flange, if removed.

Fig 22: Using Special Tool On Front Flange
Courtesy of FORD MOTOR CO.
Install the front flange and a new front output nut.
- Use the special tool to prevent the flange from turning.
- Tighten to 223 Nm (164 lb-ft).
  
  Fig 23: Using Special Tool On Flange
  Courtesy of FORD MOTOR CO.

NOTE: Rotate the sector assembly to the 4-wheel high position for easy installation.

Fig 24: Locating Range Shift Sleeve Front Case

G04650956

Courtesy of FORD MOTOR CO.

Position the range fork assembly and the range shift sleeve in the front case.
Position the drive sprocket hub on the mainshaft.

Fig 25: Locating Drive Sprocket Hub On Mainshaft
Courtesy of FORD MOTOR CO.
Install the mode hub.

NOTE: The thin side of the synchronizer or mode sleeve must face upward.

Fig 26: Locating Shift Rail And Mode Sleeve

G04650958

Courtesy of FORD MOTOR CO.

Assemble the mode fork, the shift rail and the mode sleeve.
Install the mode fork and the shift rail assembly in the front case.
- The shift rail must bottom in the case.
  
  Fig 27: Installing Mode Fork And Shift Rail Assembly Front Case
  Courtesy of FORD MOTOR CO.

CAUTION: Install the mainshaft assembly so that the synchronizer strut bears against one of the mode sleeve teeth.

Fig 28: Installing Mainshaft Assembly

G04650960

Courtesy of FORD MOTOR CO.

Install the mainshaft.
Install the clutch gear.

Fig 29: Installing Clutch Gear
Courtesy of FORD MOTOR CO.
Install the drive sprocket, the driven sprocket and the drive chain as an assembly.

Fig 30: Installing Drive Sprocket
Courtesy of FORD MOTOR CO.
Install the mode spring.

Fig 31: Locating Mode Spring
Courtesy of FORD MOTOR CO.
Install a new drive sprocket retaining ring.

Fig 32: Locating Drive Sprocket Retaining Ring
Courtesy of FORD MOTOR CO.
Install a new driven sprocket retaining ring.

Fig 33: Locating Driven Sprocket Retaining Ring
Courtesy of FORD MOTOR CO.
Using the special tools and a suitable press, install a new ball bearing.

Fig 34: Using Special Tool On Ball Bearing
Courtesy of FORD MOTOR CO.
Install a new ball bearing retaining ring.

Fig 35: Locating Ball Bearing Retaining Ring
Courtesy of FORD MOTOR CO.

NOTE: The identification numbers on the bearing must face the special tool.

Fig 36: Using Special Tool On Needle Bearing

G04650968

Courtesy of FORD MOTOR CO.

Using the special tools and a suitable press, install a new needle bearing.
Install the chip collector magnet.

Fig 37: Locating Chip Collector Magnet
Courtesy of FORD MOTOR CO.
Install the oil tube.

Fig 38: Locating Oil Tube
Courtesy of FORD MOTOR CO.
Clean both case mating surfaces with metal surface cleaner.

NOTE: The silicone bead must be no larger than 2 mm (0.08 in) in diameter.

Apply a bead of silicone gasket and sealant to the joint face of the case.
- The bead must be on the inside of the bolt holes, toward the inside of the case.
Position the rear case half onto the front case half.

Fig 39: Locating Rear Case Half Onto Front Case Half
Courtesy of FORD MOTOR CO.

NOTE: Use a crisscross pattern when tightening the bolts.

Install the 25 new case bolts.
- Tighten to 31 Nm (23 lb-ft).
  
  Fig 40: Locating Case Bolt
  Courtesy of FORD MOTOR CO.
Install the new retaining ring.
1. Install the special tool.
2. Install the new retaining ring.
  - Remove the special tool.
    
    Fig 41: Using Special Tool On Retaining Ring
    Courtesy of FORD MOTOR CO.

NOTE: Prior to assembly, verify that the O-ring is in the oil pump pickup inlet.

Fig 42: Locating Oil Pump Assembly Onto Mainshaft

G04650974

Courtesy of FORD MOTOR CO.

Slide the oil pump assembly onto the mainshaft and connect the oil tube.

NOTE: The identification numbers on the needle bearing must face the special tool.

Fig 43: Using Special Tool On Needle Bearing

G04650975

Courtesy of FORD MOTOR CO.

Using the special tools and a suitable press, install a new needle bearing.
Clean the rear case and rear retainer mating surfaces with metal surface cleaner.
Apply a bead of silicone gasket and sealant to the rear retainer joint face.

Fig 44: Locating Rear Retainer Joint Face
Courtesy of FORD MOTOR CO.
Position the rear retainer on the rear case.

Fig 45: Locating Rear Retainer On Rear Case
Courtesy of FORD MOTOR CO.
Install the 8 new rear retainer bolts.
- Tighten to 31 Nm (23 lb-ft).
  
  Fig 46: Locating Rear Retainer Bolts
  Courtesy of FORD MOTOR CO.
Using the special tools, install a new rear output seal.

Fig 47: Installing Rear Output Seal
Courtesy of FORD MOTOR CO.
Using the special tools, install a new slinger on the rear flange, if removed.

Fig 48: Installing Slinger On Rear Flange
Courtesy of FORD MOTOR CO.
Install the rear flange and a new output nut.
- Use the special tool to prevent the flange from turning.
- Tighten to 251 Nm (186 lb-ft).
  
  Fig 49: Installing Rear Flange And Output Nut
  Courtesy of FORD MOTOR CO.

CAUTION: Do not use air tools.

Install the drain and fill plugs.
- Tighten to 27 Nm (20 lb-ft).
  
  Fig 50: Locating Drain And Fill Plugs
  Courtesy of FORD MOTOR CO.
Install the 3 position switch.
- Tighten to 27 Nm (20 lb-ft).
  
  Fig 51: Locating Position Switch
  Courtesy of FORD MOTOR CO.
Tighten the shift lever nut to 20 Nm (15 lb-ft).

Fig 52: Locating Shift Lever Nut
Courtesy of FORD MOTOR CO.
Remove the transfer case from the special tool.

Fig 53: Using Special Tool On Transfer Case
Courtesy of FORD MOTOR CO.