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Home >> Ford >> 2006 >> Focus ZX5 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 777 (Transfer Case - F250-F550 Super Duty) >> Disassembly And Assembly >> Transfer Case - Electronic Shift >> Assembly

Transfer Case - Electronic 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: Using Special Tool On Motor Adapter
    GF0007577Courtesy of FORD MOTOR CO.
  2. Using the special tool, install the motor adapter.
  3. Install the sector assembly. On the electric shift transfer case, install the plastic retainer and the O-ring.
    Fig 3: Identifying Sector Assembly
    GF0007579Courtesy of FORD MOTOR CO.
    4. NOTE: If installing a new poppet spring, it must be like in color to the original poppet spring.
    Fig 4: Identifying Poppet Screw, Spring And Poppet
    GF0007575Courtesy of FORD MOTOR CO.
  4. Assemble the poppet screw, the spring and the poppet.
  5. Install the poppet assembly.
    • Tighten to 20 N.m (15 lb-ft).
    Fig 5: Locating Poppet Assembly
    GF0007580Courtesy of FORD MOTOR CO.
  6. Install the rear input gear thrust washer.
    Fig 6: Identifying Rear Input Gear Thrust Washer
    GF0007572Courtesy of FORD MOTOR CO.
  7. Install the front input gear thrust washer.
    Fig 7: Identifying Front Input Gear Thrust Washer
    GF0007571Courtesy of FORD MOTOR CO.
    8. NOTE: Install the lock plate with the stamped letter E facing outward.
    Fig 8: Identifying Lock Plate
    GF0007570Courtesy of FORD MOTOR CO.
  8. Install the lock plate.
  9. Place the input gear into the planetary carrier assembly.
    Fig 9: Identifying Input Gear Into Planetary Carrier Assembly
    GF0007569Courtesy of FORD MOTOR CO.
  10. Install a new lock plate retaining ring.
    Fig 10: Identifying Lock Plate Retaining Ring
    GF0007568Courtesy of FORD MOTOR CO.
  11. Using the special tools and a suitable press, install a new front input bearing.
    Fig 11: Using Special Tool On Front Input Bearing
    GF0007581Courtesy of FORD MOTOR CO.
  12. Install a new bearing retainer ring.
    Fig 12: Identifying Bearing Retainer Ring
    GF0007561Courtesy of FORD MOTOR CO.
  13. Position the planetary assembly into the front case.
    Fig 13: Positioning Planetary Assembly Into Front Case
    GF0007560Courtesy of FORD MOTOR CO.
  14. Install a new retaining ring.
    1. Install the special tool.
    2. Install a new retaining ring.
    • Remove the special tool.
    Fig 14: Identifying Retaining Ring
    GF0007582Courtesy of FORD MOTOR CO.
  15. Using the special tools, install a new input seal.
    Fig 15: Using Special Tool On Input Seal
    GF0007583Courtesy of FORD MOTOR CO.
  16. Using the special tools and a suitable press, install a new front output ball bearing.
    Fig 16: Installing Front Output Ball Bearing
    GF0007584Courtesy of FORD MOTOR CO.
  17. Install a new front output ball bearing retaining ring.
    Fig 17: Installing Front Output Ball Bearing Retaining Ring
    GF0007566Courtesy of FORD MOTOR CO.
  18. Position the front output shaft in the front case.
    Fig 18: Positioning Front Output Shaft In Front Case
    GF0007585Courtesy of FORD MOTOR CO.
  19. Install a new retaining ring.
    1. Install the special tool.
    2. Install a new retaining ring.
    • Remove the special tool.
    Fig 19: Identifying Retaining Ring
    GF0007586Courtesy of FORD MOTOR CO.
  20. Using the special tools, install a new front output seal.
    Fig 20: Installing Front Output Seal
    GF0007587Courtesy of FORD MOTOR CO.
  21. Using the special tools, install a new slinger on the front flange, if removed.
    Fig 21: Using Special Tool On Front Flange
    GF0007588Courtesy of FORD MOTOR CO.
  22. 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 22: Using Special Tool On Flange
    GF0007589Courtesy of FORD MOTOR CO.
    23. NOTE: Rotate the sector assembly to the 4-wheel high position for easy installation.
    Fig 23: Positioning Range Fork Assembly And Range Shift Sleeve
    GF0007556Courtesy of FORD MOTOR CO.
  23. Position the range fork assembly and the range shift sleeve in the front case.
  24. Position the drive sprocket hub on the mainshaft.
    Fig 24: Identifying Drive Sprocket Hub
    GF0007554Courtesy of FORD MOTOR CO.
  25. Position the inner ring on the drive sprocket.
    Fig 25: Identifying Inner Ring
    GF0007614Courtesy of FORD MOTOR CO.
  26. Position the middle ring on the inner ring.
    Fig 26: Identifying Middle Ring
    GF0007613Courtesy of FORD MOTOR CO.
  27. Position the outer ring on the middle ring.
    Fig 27: Identifying Outer Ring
    GF0007612Courtesy of FORD MOTOR CO.
  28. Position and rotate the synchronizer hub until it drops into the installed position. Install a new retaining ring.
    Fig 28: Identifying Retaining Ring
    GF0007611Courtesy of FORD MOTOR CO.
    29. NOTE: The thin side of the synchronizer or mode sleeve must face upward.
    Fig 29: Identifying Mode Fork, Shift Rail And Synchronizer Sleeve
    GF0007552Courtesy of FORD MOTOR CO.
  29. Assemble the mode fork, the shift rail and the synchronizer sleeve.
  30. Install the mode fork and the shift rail assembly in the front case.
    • The shift rail must bottom in the case.
    Fig 30: Installing Mode Fork And Shift Rail Assembly
    GF0007590Courtesy of FORD MOTOR CO.
    31. CAUTION: Install the mainshaft assembly so that the synchronizer strut bears against one of the synchronizer sleeve teeth.
    Fig 31: Installing Mainshaft
    GF0007591Courtesy of FORD MOTOR CO.
  31. Install the mainshaft.
  32. Install the clutch gear.
    Fig 32: Installing Clutch Gear
    GF0007592Courtesy of FORD MOTOR CO.
  33. Install the drive sprocket, the driven sprocket and the drive chain as an assembly.
    Fig 33: Installing Drive Sprocket, Driven Sprocket And Drive Chain
    GF0007593Courtesy of FORD MOTOR CO.
  34. Install the mode spring.
    Fig 34: Identifying Mode Spring
    GF0007549Courtesy of FORD MOTOR CO.
  35. Install a new drive sprocket retaining ring.
    Fig 35: Identifying Drive Sprocket Retaining Ring
    GF0007548Courtesy of FORD MOTOR CO.
  36. Install a new driven sprocket retaining ring.
    Fig 36: Identifying Driven Sprocket Retaining Ring
    GF0007547Courtesy of FORD MOTOR CO.
  37. Using the special tools and a suitable press, install a new ball bearing.
    Fig 37: Installing Ball Bearing
    GF0007594Courtesy of FORD MOTOR CO.
  38. Install a new ball bearing retaining ring.
    Fig 38: Identifying Ball Bearing Retaining Ring
    GF0007543Courtesy of FORD MOTOR CO.
    39. NOTE: The identification numbers on the bearing must face the special tool.
    Fig 39: Installing Needle Bearing
    GF0007595Courtesy of FORD MOTOR CO.
  39. Using the special tools and a suitable press, install a new needle bearing.
  40. Install the chip collector magnet.
    Fig 40: Identifying Chip Collector Magnet
    GF0007546Courtesy of FORD MOTOR CO.
  41. Install the oil tube.
    Fig 41: Identifying Oil Tube
    GF0007542Courtesy of FORD MOTOR CO.
  42. Clean both case mating surfaces with metal surface cleaner.
    43. NOTE: The silicone bead must be no larger than 2 mm (0.08 in) in diameter.
  43. 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.
  44. Position the rear case half onto the front case half.
    Fig 42: Positioning Rear Case Half Onto Front Case Half
    GF0007596Courtesy of FORD MOTOR CO.
    45. NOTE: Use a crisscross pattern when tightening the bolts.
    Fig 43: Identifying Case Bolts
    GF0007597Courtesy of FORD MOTOR CO.
  45. Install the 25 new case bolts.
    • Tighten to 31 N.m (23 lb-ft).
  46. Install the new retaining ring.
    1. Install the special tool.
    2. Install the new retaining ring.
    • Remove the special tool.
    Fig 44: Identifying Retaining Ring
    GF0007598Courtesy of FORD MOTOR CO.
    47. NOTE: Prior to assembly, verify that the O-ring is in the oil pump pickup inlet.
    Fig 45: Sliding Oil Pump Assembly Onto Mainshaft
    GF0007538Courtesy of FORD MOTOR CO.
  47. Slide the oil pump assembly onto the mainshaft and connect the oil tube.
    48. NOTE: The identification numbers on the needle bearing must face the special tool.
    Fig 46: Installing Needle Bearing
    GF0007599Courtesy of FORD MOTOR CO.
  48. Using the special tools and a suitable press, install a new needle bearing.
  49. Clean the rear case and rear retainer mating surfaces with metal surface cleaner.
  50. Apply a bead of gasket and sealant to the rear retainer joint face.
    Fig 47: Applying Sealant to Rear Retainer Joint Face
    GF0007600Courtesy of FORD MOTOR CO.
  51. Position the rear retainer on the rear case.
    Fig 48: Positioning Rear Retainer On Rear Case
    GF0007601Courtesy of FORD MOTOR CO.
  52. Install the 8 new rear retainer bolts.
    • Tighten to 31 N.m (23 lb-ft).
    Fig 49: Identifying Rear Retainer Bolts
    GF0007602Courtesy of FORD MOTOR CO.
  53. Using the special tools, install a new rear output seal.
    Fig 50: Installing Rear Output Seal
    GF0007603Courtesy of FORD MOTOR CO.
  54. Using the special tools, install a new slinger on the rear flange, if removed.
    Fig 51: Installing Slinger On Rear Flange
    GF0007604Courtesy of FORD MOTOR CO.
  55. Using the special tool to prevent the flange from turning, install the rear flange and a new rear output nut.
    • Tighten to 251 N.m (186 lb-ft).
    Fig 52: Installing Rear Flange and Rear Output Nut
    GF0007605Courtesy of FORD MOTOR CO.
    56. CAUTION: Do not use air tools.
    Fig 53: Identifying Fill Plugs
    GF0007606Courtesy of FORD MOTOR CO.
  56. Install the drain and fill plugs.
    • Tighten to 27 N.m (20 lb-ft).
    57. NOTE: Apply a coat of multi-purpose grease to the motor adapter.
    Fig 54: Locating Shift Motor Bolts
    GF0007615Courtesy of FORD MOTOR CO.
  57. Install the gearmotor encoder assembly.
    • Tighten shift motor bolts to 20 N.m (15 lb-ft).
  58. Remove the transfer case from the special tool.
    Fig 55: Using Special Tool On Transfer Case
    GF0007529Courtesy of FORD MOTOR CO.
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