Transfer Case - (Torque On Demand (TOD)): Assembly

WARNING: This page is about a different car, the 2007 Lincoln Mark LT and 2007 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

Lubricate all internal components with the recommended transfer case lubricant during reassembly.
Clean the mating surfaces of the cases.
Using the special tools, install the input shaft support bearing.

Fig 1: Installing Input Shaft Support Bearing
Courtesy of FORD MOTOR CO.
Using the special tools, install the front output shaft bearing.

Fig 2: Installing Front Output Shaft Bearing
Courtesy of FORD MOTOR CO.
Using the special tool, install the front yoke-to-flange seal.

Fig 3: Installing Front Yoke-To-Flange Seal
Courtesy of FORD MOTOR CO.
Using the special tools, install a new rear output seal.

Fig 4: Installing Rear Output Seal
Courtesy of FORD MOTOR CO.
Install the dust shield, if removed.

Fig 5: Installing Dust Shield
Courtesy of FORD MOTOR CO.
Install the front output shaft and snap ring.

Fig 6: Installing Front Output Shaft And Snap Ring
Courtesy of FORD MOTOR CO.
Using the special tools, install the input seal.

Fig 7: Installing Input Seal
Courtesy of FORD MOTOR CO.
Install the rear output shaft sleeve and snap ring.

Fig 8: Locating Rear Output Shaft Sleeve And Snap Ring
Courtesy of FORD MOTOR CO.
Install the output shaft.

Fig 9: Locating Output Shaft
Courtesy of FORD MOTOR CO.
Install the oil pump assembly.
- Make sure the oil pump finger is in the slot in the case
Fig 10: Locating Oil Pump Assembly
Courtesy of FORD MOTOR CO.
Install the oil pan magnet into its slot in the case.

Fig 11: Identifying Oil Pan Magnet
Courtesy of FORD MOTOR CO.
Install the output shaft hub.

Fig 12: Locating Output Shaft Hub
Courtesy of FORD MOTOR CO.
Install the thrust bearing race.

Fig 13: Locating Thrust Bearing Race
Courtesy of FORD MOTOR CO.
Install the thrust bearing.

Fig 14: Locating Thrust Bearing
Courtesy of FORD MOTOR CO.
Install the thrust bearing race.

Fig 15: Locating Thrust Bearing Race
Courtesy of FORD MOTOR CO.
Install the drive chain and the sprockets as an assembly.

Fig 16: Locating Drive Chain And Sprockets
Courtesy of FORD MOTOR CO.
Install the spacer.

Fig 17: Installing Spacer
Courtesy of FORD MOTOR CO.
Install the clutch pack assembly.

Fig 18: Locating Clutch Pack Assembly
Courtesy of FORD MOTOR CO.
Install the snap ring.

Fig 19: Locating Snap Ring
Courtesy of FORD MOTOR CO.
Install the wave spring.

Fig 20: Locating Wave Spring
Courtesy of FORD MOTOR CO.
Install the bearings and the apply cam.

Fig 21: Locating Bearings And Cam
Courtesy of FORD MOTOR CO.
Install the cam/coil housing.

Fig 22: Locating Cam/Coil Housing
Courtesy of FORD MOTOR CO.
Install the snap ring.

Fig 23: Locating Snap Ring
Courtesy of FORD MOTOR CO.
Using a suitable press and the special tool, install the rear output shaft support bearing.

Fig 24: Locating Rear Output Shaft Support Bearing
Courtesy of FORD MOTOR CO.
Using a suitable press and the special tool, install the front output shaft rear bearing.

Fig 25: Locating Front Output Shaft Rear Bearing
Courtesy of FORD MOTOR CO.
Using the special tool, install the rear output shaft bearing.

Fig 26: Installing Rear Output Shaft Bearing
Courtesy of FORD MOTOR CO.
Using the special tool, install the front output shaft bearing.

Fig 27: Installing Front Output Shaft Bearing
Courtesy of FORD MOTOR CO.
Install the coil.
1. Position the coil.
2. Install the nuts.
- Tighten to 10 Nm (89 lb-in).
Fig 28: Installing Coil
Courtesy of FORD MOTOR CO.

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.

Coat the mating surfaces of the case and cover with a small bead of sealant.
Position the 2 transfer case halves and tighten the bolts according to sequence shown.
- Tighten to 24 Nm (18 lb-ft).
Fig 29: Tightening Transfer Case Halves Bolts In Sequence
Courtesy of FORD MOTOR CO.
Install the rear output shaft snap ring.
- Lift up on the output shaft while installing the snap ring.
Fig 30: Installing Rear Output Shaft Snap Ring
Courtesy of FORD MOTOR CO.
Apply a small bead of sealant to the transfer case cover and extension housing mating surfaces.

Fig 31: Apply Small Bead Of Sealant To Transfer Case Cover And Extension Housing
Courtesy of FORD MOTOR CO.
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 32: Installing Extension Housing
Courtesy of FORD MOTOR CO.
Using the special tool, install the oil seal, if removed.

Fig 33: Installing Oil Seal
Courtesy of FORD MOTOR CO.
Install the coil wire into the shift motor electrical connector.
1. Install the coil wire and pin.
2. Install the wire connector spacer.
Fig 34: Identifying Wire Connector Spacer
Courtesy of FORD MOTOR CO.
Remove the transfer case from the special tool.

Fig 35: Removing Transfer Case From Special Tool
Courtesy of FORD MOTOR CO.
Install the transfer case in the vehicle. For additional information, refer to Transfer Case in this article.
Fill the transfer case. For additional information, refer to Transfer Case Draining and Filling .