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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 - Mechanical Shift >> Assembly

Transfer Case - Mechanical 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: Using Special Tool To Install Shift Lever Seal
    G03964970Courtesy of FORD MOTOR CO.
  1. Using the special tool, install the shift lever seal.
  2. Install the shift lever (from outside of case), shift cam, detent spring and detent roller.
    Fig 2: Installing Shift Lever, Shift Cam, Detent Spring And Detent Roller
    G03964971Courtesy of FORD MOTOR CO.
    3. NOTE: Access the shift lever set screw through the mode indicator switch hole.
    Fig 3: Identifying Mode Indicator Switch Hole
    G03964966Courtesy of FORD MOTOR CO.
  3. Tighten to 10 Nm (89 lb-in).
  4. Using a suitable press and the special tools, install the front output shaft bearing.
    Fig 4: Installing Front Output Shaft Bearing Using Suitable Press And Special Tools
    G03964885Courtesy of FORD MOTOR CO.
  5. Using the special tool, install the front yoke to flange seal.
    Fig 5: Installing Front Yoke To Flange Seal Using Special Tool
    G03964886Courtesy of FORD MOTOR CO.
  6. Install the dust shield, if removed.
    Fig 6: Installing Dust Shield
    G03964883Courtesy of FORD MOTOR CO.
  7. Install the front output shaft.
    1. Position the front output shaft.
    2. Install the front output shaft snap ring.
    Fig 7: Installing Front Output Shaft
    G03964888Courtesy of FORD MOTOR CO.
  8. Using a press and a suitable bearing installer, install the front planet carrier bearing. Install the front planet carrier bearing snap ring.
    Fig 8: Using Press And Suitable Bearing Installer To Install Front Planet Carrier Bearing
    G03964878Courtesy of FORD MOTOR CO.
  9. Install the ring gear.
    • Position the ring gear.
    • Install the ring gear snap ring.
    10. CAUTION: Do not crush the needle bearings.
    Fig 9: Using Suitable Press And Special Tool To Install Needle Bearing And Bushing Into Front Planet Carrier
    G03964890Courtesy of FORD MOTOR CO.
  10. If removed, using a suitable press and the special tool, install the needle bearing and bushing into the front planet carrier.
  11. Install the front planet carrier.
    1. Position the front planet carrier.
    2. Install the front planet carrier snap ring.
    Fig 10: Installing Front Planet Carrier
    G03964891Courtesy of FORD MOTOR CO.
  12. Using the special tools, install the input seal.
    Fig 11: Using Special Tools To Install Input Seal
    G03964892Courtesy of FORD MOTOR CO.
  13. Install the shift fork and the reduction hub.
    Fig 12: Installing Shift Fork And Reduction Hub
    G03964894Courtesy of FORD MOTOR CO.
  14. Install the shift rail.
    Fig 13: Installing Shift Rail
    G03964895Courtesy of FORD MOTOR CO.
  15. Install the oil pump and the output shaft.
    Fig 14: Installing Oil Pump And Output Shaft
    G03964896Courtesy of FORD MOTOR CO.
  16. Install the magnet into its slot in the case.
    Fig 15: Installing Magnet Into Its Slot In Case
    G03934121Courtesy of FORD MOTOR CO.
  17. Install the drive chain and sprocket assembly.
    Fig 16: Installing Drive Chain And Sprocket Assembly
    G03964898Courtesy of FORD MOTOR CO.
  18. Install the spacer.
    Fig 17: Installing Spacer
    G03964899Courtesy of FORD MOTOR CO.
    19. NOTE: If the lockup hub assembly was disassembled, carry out the following steps.
    Fig 18: Assembling Lockup Hub Assembly
    G03964900Courtesy of FORD MOTOR CO.
  19. 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.
  20. Install the lockup hub and the shift fork and spring.
    Fig 19: Installing Lockup Hub And Shift Fork And Spring
    G03964988Courtesy of FORD MOTOR CO.
  21. Install the coil housing.
    Fig 20: Installing Coil Housing
    G03964902Courtesy of FORD MOTOR CO.
  22. Install the snap ring.
    Fig 21: Installing Snap Ring
    G03964947Courtesy of FORD MOTOR CO.
  23. Using the special tool, install the rear output shaft bearing.
    Fig 22: Installing Rear Output Shaft Bearing Using Special Tool
    G03964904Courtesy of FORD MOTOR CO.
  24. Using the special tool, install the front output shaft bearing.
    Fig 23: Using Special Tool To Install Front Output Shaft Bearing
    G03964905Courtesy of FORD MOTOR CO.
  25. Install the coil.
    1. Position the coil.
    2. Install the nuts.
      • Tighten to 10 Nm (89 lb-in).
    Fig 24: Installing Coil
    G03964906Courtesy of FORD MOTOR CO.
    26. 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.
  26. Coat the mating surfaces of the case and cover with a small bead of sealant.
  27. Position the 2 transfer case halves and tighten the bolts according to sequence shown.
    • Tighten to 24 Nm (18 lb-ft).
    Fig 25: Tightening Transfer Case Halve Bolts In Sequence
    G03964907Courtesy of FORD MOTOR CO.
  28. Install the rear output shaft snap ring.
    • Lift up on the output shaft while installing the snap ring.
    Fig 26: Installing Rear Output Shaft Snap Ring
    G03964908Courtesy of FORD MOTOR CO.
    29. NOTE: Place the speed sensor tone wheel into a suitable gear and bearing heater. Heat the tone wheel to 425°F.
    Fig 27: Installing Speed Sensor Tone Wheel
    G03964996Courtesy of FORD MOTOR CO.
  29. Install the speed sensor tone wheel, if equipped.
    1. Install the tone wheel spacer clip against the snap ring.
    2. Slide the heated tone wheel onto the output shaft. Position it against the spacer.
  30. Apply a small bead of sealant to the transfer case cover and extension housing mating surfaces.
    Fig 28: Applying Small Bead Of Sealant To Transfer Case Cover And Extension Housing Mating Surfaces
    G03964909Courtesy of FORD MOTOR CO.
  31. 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 29: Installing Extension Housing
    G03964910Courtesy of FORD MOTOR CO.
  32. Using the special tool, install the oil seal, if removed.
    Fig 30: Installing Oil Seal Using Special Tool
    G03964911Courtesy of FORD MOTOR CO.
  33. Install the coil wire in the electrical connector.
    • Install the coil wire and pin.
      • Install the wire connector spacer.
    Fig 31: Installing Coil Wire In Electrical Connector
    G03964937Courtesy of FORD MOTOR CO.
  34. Install the OSS sensor.
    Fig 32: Installing OSS Sensor
    G03964938Courtesy of FORD MOTOR CO.
  35. Install the mode indicator switch.
    • Tighten to 41 Nm (30 lb-ft).
    Fig 33: Installing Mode Indicator Switch
    G03964934Courtesy of FORD MOTOR CO.
  36. Remove the transfer case from the special tool.
    Fig 34: Removing Transfer Case From Special Tool
    G03964850Courtesy of FORD MOTOR CO.
  37. Install the transfer case in the vehicle. Refer to TRANSFER CASE .
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