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Transfer Case - Mechanical Shift: Assembly

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install a new support O-ring seal.
    Fig 1: Identifying Support O-Ring Seal
    GF0007578Courtesy of FORD MOTOR CO.
    2. NOTE: Prior to installation, coat the threads with thread sealant.
    Fig 2: Installing Sector Shaft Support
    GF0007577Courtesy of FORD MOTOR CO.
  2. Using the special tool, install the sector shaft support.
    • Tighten to 31 N.m (23 lb-ft).
  3. Install the sector assembly.
    Fig 3: Installing Sector Assembly
    GF0007579Courtesy of FORD MOTOR CO.
  4. Install the spacer, the lever, the washer and the locknut.
    Fig 4: Identifying Spacer, Lever, Washer And Locknut
    GF0007576Courtesy of FORD MOTOR CO.
    5. NOTE: If installing a new poppet spring, it must be like in color to the original poppet spring.
    Fig 5: Identifying Poppet Screw, Spring And Poppet
    GF0007575Courtesy of FORD MOTOR CO.
  5. Assemble the poppet screw, the spring and the poppet.
  6. Install the poppet assembly.
    • Tighten to 20 N.m (15 lb-ft).
    Fig 6: Identifying Poppet Assembly
    GF0007580Courtesy of FORD MOTOR CO.
  7. Install the rear input gear thrust washer.
    Fig 7: Identifying Rear Input Gear Thrust Washer
    GF0007572Courtesy of FORD MOTOR CO.
  8. Install the front input gear thrust washer.
    Fig 8: Identifying Front Input Gear Thrust Washer
    GF0007571Courtesy of FORD MOTOR CO.
    9. NOTE: Install the lock plate with the stamped letter E facing outward.
    Fig 9: Identifying Lock Plate
    GF0007570Courtesy 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
    GF0007569Courtesy of FORD MOTOR CO.
  11. Install a new lock plate retaining ring.
    Fig 11: Identifying Lock Plate Retaining Ring
    GF0007568Courtesy 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 Tools
    GF0007581Courtesy of FORD MOTOR CO.
  13. Install a new bearing retainer ring.
    Fig 13: Identifying Bearing Retainer Ring
    GF0007561Courtesy of FORD MOTOR CO.
  14. Position the planetary assembly into the front case.
    Fig 14: Positioning Planetary Assembly Into Front Case
    GF0007560Courtesy 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: Identifying Retainer Ring
    GF0007582Courtesy of FORD MOTOR CO.
  16. Using the special tools, install a new input seal.
    Fig 16: Installing Input Seal Using Special Tool
    GF0007583Courtesy 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
    GF0007584Courtesy of FORD MOTOR CO.
  18. Install a new front output ball bearing retaining ring.
    Fig 18: Identifying Front Output Ball Bearing Retaining Ring
    GF0007566Courtesy of FORD MOTOR CO.
  19. Position the front output shaft in the front case.
    Fig 19: Positioning Front Output Shaft
    GF0007585Courtesy 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: Identifying Retaining Ring
    GF0007586Courtesy of FORD MOTOR CO.
  21. Using the special tools, install a new front output seal.
    Fig 21: Installing Front Output Seal
    GF0007587Courtesy 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
    GF0007588Courtesy of FORD MOTOR CO.
  23. Using the special tool to prevent the flange from turning, install the front flange and a new front output nut.
    • Tighten to 223 N.m (164 lb-ft).
    Fig 23: Installing Front Flange And Front Output Nut
    GF0007589Courtesy of FORD MOTOR CO.
    24. NOTE: Rotate the sector assembly to the 4-wheel high position for easy installation.
    Fig 24: Positioning Range Fork Assembly And Range Shift Sleeve
    GF0007556Courtesy 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
    GF0007554Courtesy of FORD MOTOR CO.
  26. Install the mode hub.
    27. NOTE: The thin side of the synchronizer or mode sleeve must face upward.
    Fig 26: Identifying Mode Fork, Shift Rail And Mode Sleeve
    GF0007552Courtesy of FORD MOTOR CO.
  27. Assemble the mode fork, the shift rail and the mode sleeve.
  28. 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
    GF0007590Courtesy of FORD MOTOR CO.
    29. CAUTION: Install the mainshaft assembly so that the synchronizer strut bears against one of the mode sleeve teeth. If not installed correctly, the synchronizer will bind.
    Fig 28: Installing Mainshaft
    GF0007591Courtesy of FORD MOTOR CO.
  29. Install the mainshaft.
  30. Install the clutch gear.
    Fig 29: Installing Clutch Gear
    GF0007592Courtesy of FORD MOTOR CO.
  31. Install the drive sprocket, the driven sprocket and the drive chain as an assembly.
    Fig 30: Installing Drive Sprocket, Driven Sprocket And Drive Chain
    GF0007593Courtesy of FORD MOTOR CO.
  32. Install the mode spring.
    Fig 31: Identifying Mode Spring
    GF0007549Courtesy of FORD MOTOR CO.
  33. Install a new drive sprocket retaining ring.
    Fig 32: Identifying Drive Sprocket Retaining Ring
    GF0007548Courtesy of FORD MOTOR CO.
  34. Install a new driven sprocket retaining ring.
    Fig 33: Identifying Driven Sprocket Retaining Ring
    GF0007547Courtesy of FORD MOTOR CO.
  35. Using the special tools and a suitable press, install a new ball bearing.
    Fig 34: Installing Ball Bearing
    GF0007594Courtesy of FORD MOTOR CO.
  36. Install a new ball bearing retaining ring.
    Fig 35: Identifying Ball Bearing Retaining Ring
    GF0007543Courtesy of FORD MOTOR CO.
    37. NOTE: The identification numbers on the bearing must face the special tool.
    Fig 36: Installing Needle Bearing
    GF0007595Courtesy of FORD MOTOR CO.
  37. Using the special tools and a suitable press, install a new needle bearing.
  38. Install the chip collector magnet.
    Fig 37: Identifying Chip Collector Magnet
    GF0007546Courtesy of FORD MOTOR CO.
  39. Install the oil tube.
    Fig 38: Identifying Oil Tube
    GF0007542Courtesy of FORD MOTOR CO.
  40. Clean both case mating surfaces with metal surface cleaner.
    41. NOTE: The silicone bead must be no larger than 2 mm (0.08 in) in diameter.
  41. Apply a bead of 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.
  42. Position the rear case half onto the front case half.
    Fig 39: Positioning Rear Case Half Onto Front Case Half
    GF0007596Courtesy of FORD MOTOR CO.
    43. NOTE: Use a crisscross pattern when tightening the bolts.
    Fig 40: Locating Case Bolts
    GF0007597Courtesy of FORD MOTOR CO.
  43. Install the 25 new case bolts.
    • Tighten to 31 N.m (23 lb-ft).
  44. Install the new retaining ring.
    1. Install the special tool.
    2. Install the new retaining ring.
    • Remove the special tool.
    Fig 41: Identifying Retaining Ring
    GF0007598Courtesy of FORD MOTOR CO.
    45. NOTE: Prior to assembly, verify that the O-ring is in the oil pump pickup inlet.
    Fig 42: Sliding Oil Pump Assembly Onto Mainshaft
    GF0007538Courtesy of FORD MOTOR CO.
  45. Slide the oil pump assembly onto the mainshaft and connect the oil tube.
    46. NOTE: The identification numbers on the needle bearing must face the special tool.
    Fig 43: Using Special Tool On Needle Bearing
    GF0007599Courtesy of FORD MOTOR CO.
  46. Using the special tools and a suitable press, install a new needle bearing.
  47. Clean the rear case and rear retainer mating surfaces with metal surface cleaner.
  48. Apply a bead of gasket and sealant to the rear retainer joint face.
    Fig 44: Applying Sealant To Rear Retainer Joint Face
    GF0007600Courtesy of FORD MOTOR CO.
  49. Position the rear retainer on the rear case.
    Fig 45: Positioning Rear Retainer On Rear Case
    GF0007601Courtesy of FORD MOTOR CO.
  50. Install the 8 new rear retainer bolts.
    • Tighten to 31 N.m (23 lb-ft).
    Fig 46: Identifying Rear Retainer Bolts
    GF0007602Courtesy of FORD MOTOR CO.
  51. Using the special tools, install a new rear output seal.
    Fig 47: Installing Rear Output Seal Using Special Tools
    GF0007603Courtesy of FORD MOTOR CO.
  52. Using the special tools, install a new slinger on the rear flange, if removed.
    Fig 48: Installing Slinger On Rear Flange Using Special Tool
    GF0007604Courtesy of FORD MOTOR CO.
  53. Using the special tool to prevent the flange from turning, install the rear flange and a new output nut.
    • Tighten to 251 N.m (186 lb-ft).
    Fig 49: Installing Rear Flange And Output Nut
    GF0007605Courtesy of FORD MOTOR CO.
    54. CAUTION: Do not use air tools.
    Fig 50: Locating Drain And Fill Plugs
    GF0007606Courtesy of FORD MOTOR CO.
  54. Install the drain and fill plugs.
    • Tighten to 27 N.m (20 lb-ft).
  55. Install the 3-position switch.
    • Tighten to 27 N.m (20 lb-ft).
    Fig 51: Locating 3-Position Switch
    GF0007607Courtesy of FORD MOTOR CO.
  56. Tighten the shift lever nut to 20 N.m (15 lb-ft).
    Fig 52: Locating Shift Lever Nut
    GF0007608Courtesy of FORD MOTOR CO.
  57. Remove the transfer case from the special tool.
    Fig 53: Using Special Tool On Transfer Case
    GF0007529Courtesy of FORD MOTOR CO.
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