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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1031 (Transfer Case -- F150 Pickup) >> Disassembly And Assembly >> Transfer Case - Electronic Shift >> Assembly

Transfer Case - Electronic Shift: Assembly

WARNING: This page is about a different car, the 2005 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Do not crush the seal.
    Fig 1: Installing Electric Shift Motor Seal Using Special Tool
    G03964884Courtesy of FORD MOTOR CO.
  1. Using the special tool, install the electric shift motor seal.
  2. Using a suitable press and the special tools, install the front output shaft bearing.
    Fig 2: Using Suitable Press And Special Tools To Install Front Output Shaft Bearing
    G03964885Courtesy of FORD MOTOR CO.
  3. Using the special tool, install the front yoke to flange seal.
    Fig 3: Using Special Tool To Install Front Yoke To Flange Seal
    G03964886Courtesy of FORD MOTOR CO.
  4. Install the dust shield, if removed.
    Fig 4: Installing Dust Shield
    G03964883Courtesy of FORD MOTOR CO.
  5. Install the front output shaft.
    1. Position the front output shaft.
    2. Install the front output shaft snap ring.
    Fig 5: Installing Front Output Shaft
    G03964888Courtesy of FORD MOTOR CO.
  6. Using a press and a suitable bearing installer, install the front planet carrier bearing. Install the front planet carrier bearing snap ring.
    Fig 6: Using Press And Bearing Installer To Install Front Planet Carrier Bearing
    G03964878Courtesy of FORD MOTOR CO.
  7. Install the ring gear.
    • Position the ring gear.
    • Install the ring gear snap ring.
    8. CAUTION: Do not crush the needle bearings.
    Fig 7: Using Suitable Press And Special Tool To Install Needle Bearing And Bushing Into Front Planet Carrier
    G03964890Courtesy of FORD MOTOR CO.
  8. If removed, using a suitable press and the special tool, install the needle bearing and bushing into the front planet carrier.
  9. Install the front planet carrier.
    1. Position the front planet carrier.
    2. Install the front planet carrier snap ring.
    Fig 8: Installing Front Planet Carrier
    G03964891Courtesy of FORD MOTOR CO.
  10. Using the special tools, install the input seal.
    Fig 9: Using Special Tools To Install Input Seal
    G03964892Courtesy of FORD MOTOR CO.
  11. Install the electric shift cam assembly.
    Fig 10: Installing Electric Shift Cam Assembly
    G03964893Courtesy of FORD MOTOR CO.
  12. Install the shift fork and the reduction hub.
    Fig 11: Installing Shift Fork And Reduction Hub
    G03964894Courtesy of FORD MOTOR CO.
  13. Install the shift rail.
    Fig 12: Installing Shift Rail
    G03964895Courtesy of FORD MOTOR CO.
  14. Install the oil pump and the output shaft.
    Fig 13: Installing Oil Pump And Output Shaft
    G03964896Courtesy of FORD MOTOR CO.
  15. Install the magnet into its slot in the case.
    Fig 14: Installing Magnet Into Its Slot In Case
    G03934121Courtesy of FORD MOTOR CO.
  16. Install the drive chain and sprocket assembly.
    Fig 15: Installing Drive Chain And Sprocket Assembly
    G03964898Courtesy of FORD MOTOR CO.
  17. Install the spacer.
    Fig 16: Installing Spacer
    G03964899Courtesy of FORD MOTOR CO.
    18. NOTE: If the lockup hub assembly was disassembled, carry out the following steps.
    Fig 17: Assembling Lockup Hub Assembly
    G03964900Courtesy of FORD MOTOR CO.
  18. Assemble the lockup hub assembly.
    1. Position the lockup collar.
    2. Install the lockup collar springs.
    3. Install the lockup hub.
    4. Install the armature.
    5. Install the lockup hub snap ring.
  19. Install the lockup hub and the shift fork and spring.
    Fig 18: Installing Lockup Hub, Shift Fork And Spring
    G03964988Courtesy of FORD MOTOR CO.
  20. Install the coil housing.
    Fig 19: Installing Coil Housing
    G03964902Courtesy of FORD MOTOR CO.
  21. Install the snap ring.
    Fig 20: Installing Snap Ring
    G03964947Courtesy of FORD MOTOR CO.
  22. Using the special tool, install the rear output shaft bearing.
    Fig 21: Installing Rear Output Shaft Bearing Using Special Tool
    G03964904Courtesy of FORD MOTOR CO.
  23. Using the special tool, install the front output shaft bearing.
    Fig 22: Using Special Tool Install Front Output Shaft Bearing
    G03964905Courtesy of FORD MOTOR CO.
  24. Install the coil.
    1. Position the coil.
    2. Install the nuts.
      • Tighten to 10 Nm (89 lb-in).
    Fig 23: Installing Coil Nuts
    G03964906Courtesy of FORD MOTOR CO.
    25. CAUTION: If too much silicone rubber is used when sealing the cover to the case, the excess sealant can plug the fluid filter and cause case failure.
  25. Coat the mating surfaces of the case and cover with a small bead of sealant.
  26. Position the 2 transfer case halves and tighten the bolts according to sequence shown.
    • Tighten to 24 Nm (18 lb-ft).
    Fig 24: Tightening Transfer Case Halves Bolts In Sequence
    G03964907Courtesy of FORD MOTOR CO.
  27. Install the rear output shaft snap ring.
    • Lift up on the output shaft while installing the snap ring.
    Fig 25: Installing Rear Output Shaft Snap Ring
    G03964908Courtesy of FORD MOTOR CO.
  28. Apply a small bead of sealant to the transfer case cover and extension housing mating surfaces.
    Fig 26: Applying Small Bead Of Sealant To Transfer Case Cover And Extension Housing Mating Surfaces
    G03964909Courtesy of FORD MOTOR CO.
  29. Install the extension housing.
    1. Position the brown clutch coil wire through its hole in the extension housing.
    2. Position the extension housing.
    3. Install the extension housing bolts.
      • Tighten to 24 Nm (18 lb-ft).
    Fig 27: Installing Extension Housing
    G03964910Courtesy of FORD MOTOR CO.
  30. Using the special tool, install the oil seal, if removed.
    Fig 28: Using Special Tool To Install Oil Seal
    G03964911Courtesy of FORD MOTOR CO.
    31. NOTE: Tighten the 3 motor bolts first, then the bracket bolt.
    Fig 29: Installing Transfer Case Shift Motor
    G03964912Courtesy of FORD MOTOR CO.
  31. Install the transfer case shift motor.
    • Tighten to 10 Nm (89 lb-in).
  32. Install the coil wire into the shift motor electrical connector.
    • Install the coil wire and pin.
    • Install the ground wire and pin.
    • Install the wire connector spacer.
    Fig 30: Installing Coil Wire Into Shift Motor Electrical Connector
    G03964853Courtesy of FORD MOTOR CO.
  33. Remove the transfer case from the special tool.
    Fig 31: Removing Transfer Case From Special Tool
    G03964850Courtesy of FORD MOTOR CO.
  34. Install the transfer case in the vehicle. For additional information, refer to TRANSFER CASE .
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