Transfer Case

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Special Tool(s) / General Equipment

Courtesy of FORD MOTOR COMPANY	100-001 (T50T-100-A) Slide Hammer
Courtesy of FORD MOTOR COMPANY	205-126 (T78P-4851-A) Holding Fixture, Drive Pinion Flange
Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W) Handle
Courtesy of FORD MOTOR COMPANY	205-241 (T86P-3514-A) Remover, Halfshaft T86P-1000-S TKIT-2009TC-F TKIT-1986-F
Courtesy of FORD MOTOR COMPANY	205-346 (T95T-1175-C) Installer, Front Axle Bushing TKIT-1995-FLM TKIT-1995-F/FM/LT TKIT-1996-LMH/MH
Courtesy of FORD MOTOR COMPANY	205-883 Installer, PTU Linkshaft Seal TKIT-2007FA-FLM
Courtesy of FORD MOTOR COMPANY	205-907 Handle, 32 Driver TKIT-2008DH-FLM
Courtesy of FORD MOTOR COMPANY	206-040 (T88T-2598-F) Installer, Parking Brake Bearing TKIT-1988-FLM TKIT-1988-F
Courtesy of FORD MOTOR COMPANY	307-003 (T57L-500-B) Holding Fixture, Transmission
Courtesy of FORD MOTOR COMPANY	307-523 Remover, Output Flange TKIT-2005S1-F
Courtesy of FORD MOTOR COMPANY	308-125 Remover, Transfer Case Bearing TKIT-1987-LM TKIT-1987-FLM
Courtesy of FORD MOTOR COMPANY	308-221 (T94P-7025-BH) Installer, Shaft Bearing Cup TKIT-1994-LMH/MH2 TKIT-1994-FH/FMH/FLMH
Courtesy of FORD MOTOR COMPANY	308-430 Installer, PTO Drive Gear Outer Oil Seal TKIT-2001-FLM TKIT-2001-ROW TKIT-2002N-LM TKIT-2002-M
Courtesy of FORD MOTOR COMPANY	308-431 Installer, Halfshaft Oil Seal TKIT-2001-FLM TKIT-2001-ROW TKIT-2002N-LM TKIT-2002-M
Courtesy of FORD MOTOR COMPANY	308-777 Remover and Installer, PTU Input Shaft Seal
Slide Hammer Dent Puller
Slide Hammer
Flat-Bladed Screwdriver
Spatula

Materials

Name	Specification
Motorcraft® Ultra Silicone Sealant TA-29	-
Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound XG-3-A	ESE-M1C171-A
Motorcraft® SAE 75W-140 Synthetic Rear Axle Lubricant XY-75W140-QL	WSL-M2C192-A

All vehicles

Remove the PTU (Power Transfer Unit). Refer to: Transfer Case .
Using the special tool, secure the PTU (Power Transfer Unit) to the bench. Use Special Service Tool: 307-003 (T57L-500-B) Holding Fixture, Transmission.

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Inspect the case exterior for cracks.

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Remove the temperature sensor clip bracket.

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NOTE: The following instruction will prevent the 308-125 (T87P-7120-D) from opening too far which would make removing the intermediate shaft seal deflector difficult.

Place a 16mm (5/8 in) washer on the special tool as shown. Use Special Service Tool: 308-125 Remover, Transfer Case Bearing.

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NOTE: The intermediate shaft seal deflector may break when removed. Remove all foreign materials from the PTU before continuing with the repair.

Using the special tools, remove and discard the halfshaft deflector. Use Special Service Tool: 205-241 (T86P-3514-A) Remover, Halfshaft, 308-125 Remover, Transfer Case Bearing. Use the General Equipment: Slide Hammer

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Using the special tool, remove and discard the halfshaft intermediate shaft seal and alignment washer. Use Special Service Tool: 205-241 (T86P-3514-A) Remover, Halfshaft, 308-125 Remover, Transfer Case Bearing. Use the General Equipment: Slide Hammer

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NOTE: There is a bearing inside the PTU directly behind the cover seal. The bearing is not serviced.

Using the special tools, remove and discard the RH cover seal. Use Special Service Tool: 205-241 (T86P-3514-A) Remover, Halfshaft. Use the General Equipment: Slide Hammer Dent Puller

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Remove and discard the compression seal.

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NOTE: Do not press the seals lower than specified. Excessive force will damage the bearing below the seals.

NOTE: Both seals will need to be pressed lower into the transfer case input shaft opening to break the seals outer sealant loose from the transfer case.

NOTE: There is approximately a 5 mm (0.196 in) air gap between both seals and approximately 1 mm (0.039 in) air gap between the inner seal and the bearing race.

Using the special tool, press the outer seal downward until the lower seal contacts the bearing race. Use Special Service Tool: 206-040 (T88T-2598-F) Installer, Parking Brake Bearing.

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Position the special tool above the PTU input shaft opening. Use Special Service Tool: 308-777 Remover and Installer, PTU Input Shaft Seal.

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Insert the special tool into one of the screw guide holes. Press the special tool downward until the shoulder of the punch touches the screw guide. Use Special Service Tool: 308-777 Remover and Installer, PTU Input Shaft Seal.

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NOTE: Do not overtighten the screws. Turn the 308-777 /3 until they are seated into the screw guide holes.

Install the special tool into the screw guide hole. Use Special Service Tool: 308-777 Remover and Installer, PTU Input Shaft Seal.

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Insert the special tool into the opposing screw guide hole. Press the special tool downward until the shoulder of the punch touches the screw guide. Use Special Service Tool: 308-777 Remover and Installer, PTU Input Shaft Seal.

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Install the special tool into the screw guide hole. Use Special Service Tool: 308-777 Remover and Installer, PTU Input Shaft Seal.

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Using the special tools, remove and discard the 2 input shaft seals. Use Special Service Tool: 100-001 (T50T-100-A) Slide Hammer, 308-777 Remover and Installer, PTU Input Shaft Seal.

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Vehicles without PTU cooler
Remove the PTU temperature sensor heat shield bolts and the heat shield.
Torque: 106 lb.in (12 Nm)

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Remove the PTU temperature sensor and the temperature sensor wiring retainer clip.

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Remove the drain plug.

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Remove the fill plug.

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Vehicles with PTU cooler
Remove the PTU temperature sensor heat shield bolts and the heat shield.

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If equipped with PTU cooling, remove the PTU temperature sensor.

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If equipped with PTU cooling, remove the PTU cooler housing bolts and PTU cooler housing.

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If equipped with PTU cooling, remove the PTU cooler housing gasket and discard.

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Remove the PTU cover bolts.

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WARNING: When removing the PTU cover, the fluid may emit a sulfur odor. Perform the repair in a well ventilated area to reduce exposure. Avoid getting the fluid on clothes and skin. Wear protective gloves such as Nitrile.

Remove the PTU cover. Use the General Equipment: Flat-Bladed Screwdriver

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Remove the ring gear assembly.

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Remove the idler gear shaft and the idler gear assembly

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NOTE: The position of the idler gear thrust washer

Remove and discard the washer.

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Remove the input gear assembly.

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Index mark the output pinion flange to the pinion shaft.

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Using the special tool, hold the output pinion flange. Remove and discard the pinion nut. Use Special Service Tool: 205-126 (T78P-4851-A) Holding Fixture, Drive Pinion Flange.

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Index-mark the output pinion flange to the pinion shaft. Using the special tool, remove the output pinion flange. Use Special Service Tool: 307-523 Remover, Output Flange.

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Remove and discard the output shaft seal.

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Remove the oil slinger.

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Remove the outer pinion bearing.

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Remove and discard the collapsible spacer.

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Remove the pinion gear.

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Inspect the PTU ring gears and bearing for damage. INSTALL a new PTU if damage is present.

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Inspect the PTU input gear and bearings for damage. INSTALL a new PTU if damage is present.

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Inspect the PTU pinion gear and bearing for damage. INSTALL a new PTU if damage is present.

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Inspect the PTU idler gear and bearing for damage. Replace as necessary.

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Inspect the PTU idler gear shaft for damage. Replace as necessary.

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Inspect the PTU bearing races and thrust surface for damage. INSTALL a new PTU if damage is present.

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Inspect the PTU outer pinion bearing race for damage. INSTALL a new PTU if damage is present.

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Inspect the PTU cover bearing and bearing race for damage. INSTALL a new PTU if damage is present.

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Thoroughly clean the internal components. Use a soft bristle brush to remove contamination and deposits. Allow parts to air dry. Inspect the components for damage, replace as necessary.

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Remove the contamination and deposits from the PTU housing and cover using a plastic scraper. Clean the PTU housing and cover using a soft bristle brush to remove the contamination. Clean any remaining lip seal coating that may still be present on the housing or cover bores with a wire brush. Make sure the vent fitting and housing pockets are clean and clear. Use the General Equipment: Spatula

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Clean the PTU case and cover flange sealing surfaces. Refer to: RTV Sealing Surface Cleaning and Preparation .

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To begin assembly, lightly coat the output shaft bearings in clean axle lubricant. Install the PTU output shaft into the PTU case.
Material: Motorcraft® SAE 75W-140 Synthetic Rear Axle Lubricant / XY-75W140-QL (WSL-M2C192-A)

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Install the new collapsible spacer.

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Lightly coat with clean axle lubricant and install the outer pinion bearing.
Material: Motorcraft® SAE 75W-140 Synthetic Rear Axle Lubricant / XY-75W140-QL (WSL-M2C192-A)

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Install the oil slinger.

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Using the special tool, install the output shaft seal. Use Special Service Tool: 308-430 Installer, PTO Drive Gear Outer Oil Seal.

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NOTE: Install a new output pinion flange and deflector if the output shaft seal mating surface is damaged.

Inspect the output pinion flange and deflector for damage, replace as necessary.

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NOTE: Install the output pinion flange to engage the spline as previously marked.

Install the output pinion flange.

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Using the special tool to hold the output pinion flange, install a new pinion flange nut. Use Special Service Tool: 205-126 (T78P-4851-A) Holding Fixture, Drive Pinion Flange.
Torque: 105 lb.ft (142 Nm)

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Lightly coat the input shaft bearings and gear with clean axle lubricant. Install the input shaft into the PTU case.
Material: Motorcraft® SAE 75W-140 Synthetic Rear Axle Lubricant / XY-75W140-QL (WSL-M2C192-A)

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NOTE: The kit may include a subassembly of the idler gear, bearings, shaft and thrust washer retained by a plastic ring. Remove and discard the ring.

Lightly coat the idler gear, bearings, shaft and thrust washer with clean axle lubricant. Insert the 2 new idler bearings in the idler gear bore (no orientation required). Insert the new idler shaft through bearings. Coat the thrust face in the PTU case with clean axle lubricant and install the idler gear subassembly.

Material: Motorcraft® SAE 75W-140 Synthetic Rear Axle Lubricant / XY-75W140-QL (WSL-M2C192-A)

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Lightly coat the ring gear shaft and bearings with clean axle lubricant. Install the ring gear shaft into the PTU case.
Material: Motorcraft® SAE 75W-140 Synthetic Rear Axle Lubricant / XY-75W140-QL (WSL-M2C192-A)

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Orient the idler shaft "D" by lightly fitting the cover over it and rotating to the correct position. Remove the cover.

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Make sure that the mating faces are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation .

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NOTE: If the PTU cover is not installed within 10 minutes of application of the silicone, new sealant must be applied.

Apply a continuous 3-4mm bead of sealant to the inside of the cover flange surface. Make sure there are no gaps in the sealer. Allow to set for 5-10 minutes before installing the cover.

Material: Motorcraft® Ultra Silicone Sealant / TA-29

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Noting the two dowels and the idler gear shaft orientation, carefully install cover and hand start the bolts. Tighten the bolts in 2 stages per sequence shown.
Torque: Stage 1: 27 lb.ft (37 Nm) Stage 2: 35 lb.ft (47 Nm)

Fig 1: Power Transfer Unit Cover Tightening Sequence
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NOTE: Position the inner seal above the PTU input shaft opening with the spring facing toward the PTU.

Using the special tools, install the seal. Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 308-777 Remover and Installer, PTU Input Shaft Seal.

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NOTE: Position the outer seal above the PTU input shaft opening with the spring facing away from the PTU.

Using the special tools, install the seal. Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 308-777 Remover and Installer, PTU Input Shaft Seal.

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Install the new compression seal. Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 308-777 Remover and Installer, PTU Input Shaft Seal.

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Using the special tools, install the RH cover seal. Use Special Service Tool: 308-221 (T94P-7025-BH) Installer, Shaft Bearing Cup, 308-431 Installer, Halfshaft Oil Seal, 205-907 Handle, 32 Driver.

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Place the intermediate shaft seal on the special tools with the spring side facing away from the tool. Use Special Service Tool: 205-907 Handle, 32 Driver, 205-883 Installer, PTU Linkshaft Seal.

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Using the special tools, install the intermediate shaft seal. Use Special Service Tool: 205-907 Handle, 32 Driver, 205-883 Installer, PTU Linkshaft Seal.

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Place the alignment washer on the special tool. Use Special Service Tool: 205-907 Handle, 32 Driver, 205-883 Installer, PTU Linkshaft Seal.

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NOTE: Do not use force when installing the alignment washer or damage to the washer can occur.

Using the special tool, install the alignment washer by hand, pushing it in until it bottoms against the seal. Use Special Service Tool: 205-907 Handle, 32 Driver, 205-883 Installer, PTU Linkshaft Seal.

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NOTE: Do not overheat (melt) the seal deflector. Monitor the temperature of the deflector with a suitable temperature measuring device, such as a digital temperature laser or infrared thermometer, while heating. Do not allow the temperature to exceed 100 deg. C (212 deg. F). Overheating will damage the deflector. If the deflector is damaged, a new deflector must be used.

NOTE: As an alternative method to heating the seal deflector, place the deflector in boiling water for 3 to 5 minutes. Dry off the deflector and install.

Position the deflector on the special tool using silicone brake caliper grease and dielectric compound to retain it to the installer. Using a suitable heat gun, heat the back of the tool to a minimum of 71 deg. C (160 deg. F) and a maximum of 93 deg. C (200 deg. F) by concentrating the heat across the back of the installer while rotating the tool. Once the optimum temperature is achieved on the tool, move the heat gun to the front of the tool and heat the inside of the deflector where it snaps onto the PTU shaft until the temperature of the deflector is a minimum of 93 deg. C (200 deg. F) to a maximum of 100 deg. C (212 deg. F). Use Special Service Tool: 205-346 (T95T-1175-C) Installer, Front Axle Bushing, 205-907 Handle, 32 Driver.

Material: Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A)

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Using the special tools, install the intermediate shaft deflector. Use Special Service Tool: 205-346 (T95T-1175-C) Installer, Front Axle Bushing, 205-907 Handle, 32 Driver.

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Make sure the deflector is completely seated all the way around and there are no cracks on the face. The deflector is correctly installed when the face of the deflector is recessed 3-5 mm (0.12-0.20 in) into the pocket all the way around.

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Install the PTU drain plug.
Torque: 106 lb.in (12 Nm)

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Vehicles with PTU cooler
Install the PTU cooler housing gasket.

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Clean the PTU cooler housing.

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Install the PTU cooler housing and the PTU cooler housing bolts. The PTU temperature sensor, heat shield and bolts will be installed after the fluid fill.
Torque: 106 lb.in (12 Nm)

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Vehicles without PTU cooler
NOTE: Install a new O-ring before installing the PTU temperature sensor.

Using a new O-ring, install the PTU temperature sensor and the temperature sensor wiring retainer clip.

Torque: 124 lb.in (14 Nm)

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Install the PTU temperature sensor heat shield and the bolts.
Torque: 106 lb.in (12 Nm)

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All vehicles
Install the temperature sensor clip bracket.
Torque: 89 lb.in (10 Nm)
Install the PTU. Refer to: Transfer Case .

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