Transfer Case: Assembly

All transfer cases 

1. Install a new stat-O seal.
   Fig 1: Installing Stat-O Seal

   Courtesy of FORD MOTOR CO.
NOTE: Prior to installation, coat the threads with pipe sealant.
Fig 2: Installing Sector Shaft Support Using Special Tool
Courtesy of FORD MOTOR CO.
2. Using the special tool, install the sector shaft support (motor adapter for electric shift transfer case).
3. Install the sector assembly. On the electric shift transfer case, install the plastic retainer and the O-ring.
   Fig 3: Installing Plastic Retainer And O-Ring

   Courtesy of FORD MOTOR CO.

   Manual shift transfer case 

4. Install the spacer, the lever, the washer, and the locknut.
   Fig 4: Installing Spacer, Lever, Washer, And Locknut

   Courtesy of FORD MOTOR CO.

   All transfer cases 

NOTE: If installing a new poppet spring, it must be like in color to the original poppet spring.
Fig 5: Assembling Poppet Screw, Spring, And Poppet
Courtesy of FORD MOTOR CO.
5. Assemble the poppet screw, the spring, and the poppet.
6. Install the poppet assembly.
   Fig 6: Installing Poppet Assembly

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

   Courtesy of FORD MOTOR CO.
8. Install the front input gear thrust washer.
   Fig 8: Installing Front Input Gear Thrust Washer

   Courtesy of FORD MOTOR CO.
NOTE: Install the lock plate with the stamped letter E facing outward.
Fig 9: Installing Lock Plate
Courtesy of FORD MOTOR CO.
9. Install the lock plate.
10. Place the input gear into the planetary carrier assembly.
    Fig 10: Placing Input Gear Into Planetary Carrier Assembly

    Courtesy of FORD MOTOR CO.
11. Install a new lock plate retaining ring.
    Fig 11: Installing Lock Plate Retaining Ring

    Courtesy of FORD MOTOR CO.
12. Using the special tools and a suitable press, install a new front input bearing.
    Fig 12: Installing Front Input Bearing Using Special Tool

    Courtesy of FORD MOTOR CO.
13. Install a new bearing retainer ring.
    Fig 13: Installing Bearing Retainer Ring

    Courtesy of FORD MOTOR CO.
14. Position the planetary assembly into the front case.
    Fig 14: Positioning Planetary Assembly Into Front Case

    Courtesy of FORD MOTOR CO.
15. Install a new retaining ring.
    1. Install the special tool.
    2. Install a new retaining ring.
    • Remove the special tool.
      Fig 15: Removing Special Tool

      Courtesy of FORD MOTOR CO.
16. Using the special tools, install a new input seal.
    Fig 16: Installing Input Seal Using Special Tool

    Courtesy of FORD MOTOR CO.
17. Using the special tools and a suitable press, install a new front output ball bearing.
    Fig 17: Installing Front Output Ball Bearing Using Special Tool

    Courtesy of FORD MOTOR CO.
18. Install a new front output ball bearing retaining ring.
    Fig 18: Installing Front Output Ball Bearing Retaining Ring

    Courtesy of FORD MOTOR CO.
19. Position the front output shaft in the front case.
    Fig 19: Positioning Front Output Shaft In Front Case

    Courtesy of FORD MOTOR CO.
20. Install a new retaining ring.
    1. Install the special tool.
    2. Install a new retaining ring.
    • Remove the special tool.
      Fig 20: Removing Special Tool

      Courtesy of FORD MOTOR CO.
21. Using the special tools, install a new front output seal.
    Fig 21: Installing Front Output Seal Using Special Tool

    Courtesy of FORD MOTOR CO.
22. Using the special tools, install a new slinger on the front flange, if removed.
    Fig 22: Installing Slinger On Front Flange Using Special Tool

    Courtesy of FORD MOTOR CO.
23. Install the front flange.
    • Use the special tool to prevent the flange from turning while installing a new nut.
      Fig 23: Installing Front Flange

      Courtesy of FORD MOTOR CO.
NOTE: Rotate the sector assembly to the 4-wheel high position for easy installation.
Fig 24: Positioning Range Fork Assembly And Range Shift Sleeve In Front Case
Courtesy of FORD MOTOR CO.
24. Position the range fork assembly and the range shift sleeve in the front case.
25. Position the drive sprocket hub on the mainshaft.
    Fig 25: Positioning Drive Sprocket Hub On Mainshaft

    Courtesy of FORD MOTOR CO.

    Electric shift transfer case 

26. Position the inner ring on the drive sprocket.
    Fig 26: Positioning Inner Ring On Drive Sprocket

    Courtesy of FORD MOTOR CO.
27. Position the middle ring on the inner ring.
    Fig 27: Positioning Middle Ring On Inner Ring

    Courtesy of FORD MOTOR CO.
28. Position the outer ring on the middle ring.
    Fig 28: Positioning Outer Ring On Middle Ring

    Courtesy of FORD MOTOR CO.
29. Position and rotate the synchronizer hub until it drops into the installed position. Install a new retaining ring.
    Fig 29: Installing Retaining Ring

    Courtesy of FORD MOTOR CO.

    Mechanical shift transfer case 

30. Install the mode hub.

    All transfer cases 

NOTE: The thin side of the synchronizer or mode sleeve must face upward.
31. Assemble the mode fork, the shift rail, and the sleeve.
    • Mode sleeve for mechanical shift or synchronizer sleeve for electric shift.
      Fig 30: Installing Mode Hub

      Courtesy of FORD MOTOR CO.
32. Install the mode fork and the shift rail assembly in the front case.
    • The shift rail must bottom in the case.
      Fig 31: Installing Mode Fork And Shift Rail Assembly In Front Case

      Courtesy of FORD MOTOR CO.
CAUTION: Install the mainshaft assembly so that the synchronizer strut bears against one of the synchronizer or mode sleeve teeth.
Fig 32: Installing Mainshaft
Courtesy of FORD MOTOR CO.
33. Install the mainshaft.
34. Install the clutch gear.
    Fig 33: Installing Clutch Gear

    Courtesy of FORD MOTOR CO.
35. Install the drive sprocket, the driven sprocket, and the drive chain as an assembly.
    Fig 34: Installing Drive Sprocket, Driven Sprocket, And Drive Chain Assembly

    Courtesy of FORD MOTOR CO.
36. Install the mode spring.
    Fig 35: Installing Mode Spring

    Courtesy of FORD MOTOR CO.
37. Install a new drive sprocket retaining ring.
    Fig 36: Installing Drive Sprocket Retaining Ring

    Courtesy of FORD MOTOR CO.
38. Install a new driven sprocket retaining ring.
    Fig 37: Installing Driven Sprocket Retaining Ring

    Courtesy of FORD MOTOR CO.
39. Using the special tools and a suitable press, install a new ball bearing.
    Fig 38: Installing Ball Bearing Using Special Tool

    Courtesy of FORD MOTOR CO.
40. Install a new ball bearing retaining ring.
    Fig 39: Installing Ball Bearing Retaining Ring

    Courtesy of FORD MOTOR CO.
NOTE: The identification numbers on the bearing must face the special tool.
Fig 40: Installing Needle Bearing
Courtesy of FORD MOTOR CO.
41. Using the special tools and a suitable press, install a new needle bearing.
42. Install the chip collector magnet.
    Fig 41: Installing Chip Collector Magnet

    Courtesy of FORD MOTOR CO.
43. Install the oil tube.
    Fig 42: Installing Oil Tube

    Courtesy of FORD MOTOR CO.
44. 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.
45. 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.
46. Position the rear case half onto the front case half.
    Fig 43: Positioning Rear Case Half Onto Front Case Half

    Courtesy of FORD MOTOR CO.
NOTE: Use a crisscross pattern when tightening the bolts.
Fig 44: Installing Bolts Retaining Rear Case To Front Case
Courtesy of FORD MOTOR CO.
47. Install the 25 new bolts retaining the rear case to the front case.
48. Install the new retaining ring.
    1. Install the special tool.
    2. Install the new retaining ring.
    • Remove the special tool.
      Fig 45: Removing Special Tool

      Courtesy of FORD MOTOR CO.
NOTE: Prior to assembly, verify that the O-ring is in the oil pump pickup inlet.
Fig 46: Sliding Oil Pump Assembly Onto Mainshaft
Courtesy of FORD MOTOR CO.
49. 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 47: Installing Needle Bearing
Courtesy of FORD MOTOR CO.
50. Using the special tools and a suitable press, install a new needle bearing.
51. Clean the rear case and rear retainer mating surfaces with metal surface cleaner.
52. Apply a bead of silicone gasket and sealant to the rear retainer joint face.
    Fig 48: Applying Bead Of Silicone Gasket And Sealant To Rear Retainer Joint Face

    Courtesy of FORD MOTOR CO.
53. Position the rear retainer on the rear case.
    Fig 49: Positioning Rear Retainer On Rear Case

    Courtesy of FORD MOTOR CO.
54. Install the eight new bolts retaining the rear retainer to the case.
    Fig 50: Installing Bolts Retaining Rear Retainer To Case

    Courtesy of FORD MOTOR CO.
55. Using the special tools, install a new rear output seal.
    Fig 51: Installing Rear Output Seal

    Courtesy of FORD MOTOR CO.
56. Using the special tools, install a new slinger on the rear flange, if removed.
    Fig 52: Installing Slinger On Rear Flange Using Special Tool

    Courtesy of FORD MOTOR CO.
57. Install the rear flange.
    • Use the special tool to prevent the flange from turning while installing a new nut.
      Fig 53: Installing Nut

      Courtesy of FORD MOTOR CO.
CAUTION: Do not use air tools.
Fig 54: Installing Drain And Fill Plugs
Courtesy of FORD MOTOR CO.
58. Install the drain and fill plugs.

    Electric shift transfer case 

NOTE: Apply a coat of multi-purpose grease to the motor adapter.
Fig 55: Installing Gearmotor Encoder Assembly
Courtesy of FORD MOTOR CO.
59. Install the gearmotor encoder assembly.

    Manual shift transfer case 

60. Install the 3 position switch.
    Fig 56: Installing Position Switch

    Courtesy of FORD MOTOR CO.
61. Tighten the nut.
    Fig 57: Tightening Nut

    Courtesy of FORD MOTOR CO.

    All transfer cases 

62. Remove the transfer case from the special tool.
    Fig 58: Removing Transfer Case From Special Tool

    Courtesy of FORD MOTOR CO.