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Transfer Case - Electronic Shift: 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.
    CAUTION: Do not crush the seal.
    Fig 1: Installing Electric Shift Motor Seal Using Special Tool
    GF0004133Courtesy of FORD MOTOR CO.
  1. Using the special tool, install the electric shift motor seal.
  2. Using a suitable press and the special tools, install the front output shaft bearing.
    Fig 2: Installing Front Output Shaft Bearing
    GF0004101Courtesy of FORD MOTOR CO.
  3. Using the special tool, install the front yoke to flange seal.
    Fig 3: Installing Front Yoke To Flange Seal
    GF0004102Courtesy of FORD MOTOR CO.
  4. Install the dust shield, if removed.
    Fig 4: Installing Dust Shield
    GF0004098Courtesy of FORD MOTOR CO.
  5. Install the front output shaft.
    1. Position the front output shaft.
    2. Install the front output shaft snap ring.
      Fig 5: Installing Front Output Shaft
      GF0004103Courtesy of FORD MOTOR CO.
  6. Using a press and a suitable bearing installer, install the front planet carrier bearing. Install the front planet carrier bearing snap ring.
    Fig 6: Installing Front Planet Carrier Bearing
    GF0004091Courtesy of FORD MOTOR CO.
  7. Install the ring gear.
    • Position the ring gear.
    • Install the ring gear snap ring.
    8. CAUTION: Do not crush the needle bearings.
    Fig 7: Locating Needle Bearings
    GF0004104Courtesy of FORD MOTOR CO.
  8. If removed, using a suitable press and the special tool, install the needle bearing and bushing into the front planet carrier.
  9. Install the front planet carrier.
    1. Position the front planet carrier.
    2. Install the front planet carrier snap ring.
      Fig 8: Installing Front Planet Carrier
      GF0004105Courtesy of FORD MOTOR CO.
  10. Using the special tools, install the input seal.
    Fig 9: Installing Input Seal
    GF0004106Courtesy of FORD MOTOR CO.
  11. Install the electric shift cam assembly.
    Fig 10: Installing Electric Shift Cam Assembly
    GF0004134Courtesy of FORD MOTOR CO.
  12. Install the shift fork and the reduction hub.
    Fig 11: Installing Shift Fork And Reduction Hub
    GF0004107Courtesy of FORD MOTOR CO.
  13. Install the shift rail.
    Fig 12: Installing Shift Rail
    GF0004108Courtesy of FORD MOTOR CO.
  14. Install the oil pump and the output shaft.
    Fig 13: Installing Oil Pump And Output Shaft
    GF0004109Courtesy of FORD MOTOR CO.
  15. Install the magnet into its slot in the case.
    Fig 14: Identifying Magnet
    GF0004110Courtesy of FORD MOTOR CO.
  16. Install the drive chain and sprocket assembly.
    Fig 15: Installing Drive Chain And Sprocket Assembly
    GF0004111Courtesy of FORD MOTOR CO.
  17. Install the spacer.
    Fig 16: Installing Spacer
    GF0004112Courtesy of FORD MOTOR CO.
    18. NOTE: If the lockup hub assembly was disassembled, carry out the following steps.
    Fig 17: Assembling Lockup Hub Assembly
    GF0004113Courtesy of FORD MOTOR CO.
  18. Assemble the lockup hub assembly.
    1. Position the lockup collar.
    2. Install the lockup collar springs.
    • Install the lockup hub.
    • Install the armature.
    • Install the lockup hub snap ring.
  19. Install the lockup hub and the shift fork and spring.
    Fig 18: Installing Lockup Hub, Shift Fork And Spring
    GF0004114Courtesy of FORD MOTOR CO.
  20. Install the coil housing.
    Fig 19: Installing Coil Housing
    GF0004115Courtesy of FORD MOTOR CO.
  21. Install the snap ring.
    Fig 20: Installing Snap Ring
    GF0004076Courtesy of FORD MOTOR CO.
  22. Using the special tool, install the rear output shaft bearing.
    Fig 21: Installing Rear Output Shaft Bearing
    GF0004116Courtesy of FORD MOTOR CO.
  23. Using the special tool, install the front output shaft bearing.
    Fig 22: Installing Front Output Shaft Bearing
    GF0004117Courtesy of FORD MOTOR CO.
  24. Install the coil.
    1. Position the coil.
    2. Install the nuts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 23: Installing Coil
      GF0004118Courtesy of FORD MOTOR CO.
    25. 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.
  25. Coat the mating surfaces of the case and cover with a small bead of sealant.
  26. Position the 2 transfer case halves and tighten the bolts according to sequence shown.
    • Tighten to 24 Nm (18 lb-ft).
    Fig 24: Tightening Transfer Case Halves Bolts In Sequence
    GF0004119Courtesy of FORD MOTOR CO.
  27. Install the rear output shaft snap ring.
    • Lift up on the output shaft while installing the snap ring.
    Fig 25: Installing Rear Output Shaft Snap Ring
    GF0004120Courtesy of FORD MOTOR CO.
  28. Apply a small bead of sealant to the transfer case cover and extension housing mating surfaces.
    Fig 26: Applying Small Bead Of Sealant To Transfer Case Cover And Extension Housing
    GF0004122Courtesy of FORD MOTOR CO.
  29. 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 27: Installing Extension Housing
    GF0004123Courtesy of FORD MOTOR CO.
  30. Using the special tool, install the oil seal, if removed.
    Fig 28: Installing Oil Seal
    GF0004124Courtesy of FORD MOTOR CO.
    31. NOTE: Tighten the 3 motor bolts first, then the bracket bolt.
    Fig 29: Installing Transfer Case Shift Motor
    GF0004135Courtesy of FORD MOTOR CO.
  31. Install the transfer case shift motor.
    • Tighten to 10 Nm (89 lb-in).
  32. Install the coil wire into the shift motor electrical connector.
    • Install the coil wire and pin.
    • Install the ground wire and pin.
    • Install the wire connector spacer.
    Fig 30: Installing Coil Wire Into Shift Motor Electrical Connector
    GF0004128Courtesy of FORD MOTOR CO.
  33. Remove the transfer case from the special tool.
    Fig 31: Removing Transfer Case From Special Tool
    GF0004063Courtesy of FORD MOTOR CO.
  34. Install the transfer case in the vehicle. For additional information, refer to Transfer Case  in this article.
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