Transfer Case - Mechanical Shift: Notes
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.
Special Tools
| Illustration | Tool Name | Tool Number |
|---|---|---|
| 2- or 3-Jaw Puller | 205-D027 (D80L-1013-A) | |
| Adapter for 303-224 (Handle) | 205-153 (T80T-4000-W) | |
| Holding Fixture, Drive Pinion Flange | 205-126 (T78P-4851-A) | |
| Holding Fixture, Transmission | 307-003 (T57L-500-B) | |
| Installer, Drive Pinion Bearing Cup | 205-138 (T80T-4000-D) | |
| Installer, Drive Pinion Bearing Cup | 205-140 (T80T-4000-F) | |
| Installer, Input Shaft Bearing | 308-412 | |
| Installer, Input Shaft Oil Seal | 308-408 | |
| Installer, Output Shaft Front Bearing | 308-410 | |
| Installer, Output Shaft Oil Seal | 308-403 | |
| Installer, Output Shaft Oil Slinger | 308-399 (Part of Kit 308-S398) | |
| Installer, Output Shaft Oil Slinger | 308-400 (Part of Kit 308-S398) | |
| Installer, Output Shaft Rear Bearing | 308-401 | |
| Installer, Output Shaft Rear Bearing | 308-411 | |
| Installer, Rear Axle Oil Seal | 205-155 (T80T-4000-Y) | |
| Installer, Transfer Case Needle Bearing | 308-402 | |
| Remover, Front Pump Bushing | 307-016 (T66L-7003-C2) | |
| Remover, Torque Converter Oil Seal | 307-309 (T94P-77001-BH) | |
| Sleeve, Input Shaft Snap Ring | 308-406 | |
| Sleeve, Output Shaft Front Snap Ring | 308-405 | |
| Sleeve, Output Shaft Rear Snap Ring | 308-404 | |
| Slide Hammer | 100-001 (T50T-100-A) | |
| Socket, Sector Shaft Nut | 308-407 | |
| Spreader, Transfer Case Housing | 308-396 | |
| Universal Puller Set | 303-DS005 (D80L-100-A) |
Material
| Item | Specification |
|---|---|
| Motorcraft Metal Surface Cleaner ZC-21 |
WSE-M5B392-A |
| Multi-Purpose Grease XG-4 and/or XL-5 |
ESB-M1C93-B |
| Silicone Gasket and Sealant TA-30 |
WSE-M4G323-A4 |
| Thread Sealant with PTFE TA-24 |
WSK-M2G350-A2 |
| Item | Part Number | Description |
|---|---|---|
| 1 | 7Z114 | Locknut |
| 2 | 7Z111 | Washer |
| 3 | 7B106 | Lever assembly |
| 4 | 7A148 | Spacer |
| 5 | - | Sector support seal (part of 7E321) |
| 6 | - | Sector shaft support (part of 7E321) |
| 7 | - | Support bearing (part of 7E321) |
| 8 | - | Support bearing (part of 7E321) |
| 9 | 7Z119 | O-ring sector support |
| 10 | 7L013 | Poppet screw |
| 11 | - | O-ring seal |
| 12 | 7219 | Spring |
| 13 | 7233 | Poppet |
| 14 | 7B215 | Front output seal |
| 15 | 7C016 | Slinger |
| 16 | 7B214 | Front flange |
| 17 | 7045 | Hex locknut |
| 18 | 7B215 | Input seal |
| 19 | 7079 | Input bearing retaining ring |
| 20 | 7005 | Front half case |
| 21 | 7034 | Vent |
| 22 | 7E440 | Precision 3-position switch |
| 23 | 7025 | Ball bearing, front input |
| 24 | 7N281 | Front input bearing retaining ring |
| 25 | - | Annulus gear (part of 7005) |
| 26 | 7917 | Annulus retaining ring |
| 27 | 7R516 | Lock plate retaining ring |
| 28 | 7B066 | Lock plate |
| 29 | 7Z118 | Front input gear thrust washer |
| 30 | 7017 | Input gear |
| 31 | 7120 | Pilot bearing |
| 32 | 7Z213 | Rear input gear thrust washer |
| 33 | 7A398 | Planetary carrier assembly |
| 34 | 7100 | Range shift sleeve |
| 35 | 7183 | Mode sleeve |
| 36 | 7064 | Hub retaining ring |
| 37 | 7124 | Mode hub |
| 38 | 7064 | Clutch gear retaining ring |
| 39 | 7C215 | Clutch gear |
| 40 | 7W060 | Drive sprocket hub |
| 41 | 7177 | Drive sprocket |
| 42 | 7064 | Sprocket retaining ring |
| 43 | 7061 | Mainshaft |
| 44 | 7085 | Rear retainer |
| 45 | 7118 | Needle bearing |
| 46 | 7B215 | Rear output seal |
| 47 | 7C016 | Slinger |
| 48 | 7A443 | Retainer bolt |
| 49 | 7B214 | Rear flange |
| 50 | 7045 | Nut |
| 51 | 7A149 | Oil pump assembly |
| 52 | 7R141 | Retaining ring |
| 53 | 7030 | Retaining ring |
| 54 | 7015 | Ball bearing |
| 55 | 7A010 | Fill plug |
| 56 | 7A010 | Drain plug |
| 57 | 7A443 | Rear case bolt |
| 58 | 7D362 | Dowel bushings |
| 59 | 7E290 | Chip collector magnet |
| 60 | 7A098 | Oil screen |
| 61 | 7N148 | Lower tube connector |
| 62 | 7A210 | Lower oil tube |
| 63 | 7N148 | Upper tube connector |
| 64 | 7A210 | Upper oil tube |
| 65 | 7288 | O-ring seal |
| 66 | 7127 | Needle bearing |
| 67 | 7064 | Sprocket retaining ring |
| 68 | 7A029 | Drive chain |
| 69 | 7177 | Driven sprocket |
| 70 | 7061 | Front output shaft |
| 71 | 7049 | Retaining ring |
| 72 | 7025 | Front oil pump ball bearing |
| 73 | 7917 | Front oil pump retaining ring |
| 74 | 7F063 | Sector assembly |
| 75 | 7005 | Rear case half |
| 76 | 7219 | Mode spring |
| 77 | 7289 | Mode fork assembly |
| 78 | 7C430 | Mode fork center pad |
| 79 | 7C430 | Mode fork end pads |
| 80 | 7289 | Range fork assembly |
| 81 | 7C430 | Range shift fork pad |