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Home >> Ford >> 2022 >> Bronco Raptor >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 31 (Transfer Case - 4X4 With Part Time Engagement - Manual) >> Disassembly And Assembly >> Transfer Case >> Assembly

Transfer Case: Assembly

WARNING: This page is about a different variant/trim than selected.
NOTE: Lubricate all internal components with the recommended transfer case lubricant during reassembly.
  1. Remove the contamination and deposits from the transfer case housing and cover using a plastic scraper. Clean the transfer case 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. Remove the General Equipment: Spatula
    GFD626655Courtesy of FORD MOTOR COMPANY
  2. Clean the transfer case housing and cover flange sealing surfaces. Refer to: RTV Sealing Surface Cleaning and Preparation .
    GFD626656Courtesy of FORD MOTOR COMPANY
  3. Install the plate.

    Torque: 40 lb.in (4.5 Nm)

    GFD626654Courtesy of FORD MOTOR COMPANY
  4. Using the special tools, install the input shaft bearing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-344 (T95P-7H150-A) Installer, Driven Sprocket Wheel.
    GFD626657Courtesy of FORD MOTOR COMPANY
  5. Install the input shaft bearing circlip.
    GFD626658Courtesy of FORD MOTOR COMPANY
  6. Install the planet carrier input shaft bearing. Use Special Service Tool: 308-614 Installer, Output Shaft Seal.
    GFD626659Courtesy of FORD MOTOR COMPANY
  7. NOTE: Make sure that the component is not damaged.

    Install the planet carrier input shaft bearing circlip.

    GFD626660Courtesy of FORD MOTOR COMPANY
  8. Install the planet carrier input shaft.
    GFD626661Courtesy of FORD MOTOR COMPANY
  9. Install the planet carrier circlip.
    GFD626662Courtesy of FORD MOTOR COMPANY
  10. Using hydraulic press install the planet carrier.. Use the General Equipment: Hydraulic Press
    GFD626663Courtesy of FORD MOTOR COMPANY
  11. NOTE: Make sure that the component is not damaged.

    install the planet carrier circlip.

    GFD626664Courtesy of FORD MOTOR COMPANY
  12. Install the shift fork and shift fork snap ring.
    GFD626665Courtesy of FORD MOTOR COMPANY
  13. Install the shift fork.
    GFD626644Courtesy of FORD MOTOR COMPANY
  14. NOTE: Set the H-L shift rod assembly pin into the longitudinal groove of the control shift rod.

    Install the electric shift cam assembly.

    GFD626643Courtesy of FORD MOTOR COMPANY
  15. Install the output shaft.
    GFD626642Courtesy of FORD MOTOR COMPANY
  16. Using the special tools, install the front output shaft support bearing. Use Special Service Tool: 307-181 (T87C-77000-D) Installer, Transaxle Bearing Cone., 205-090 (T75L-1165-B) Plate, Bearing/Oil Seal.. Use the General Equipment: Hydraulic Press
    GFD626666Courtesy of FORD MOTOR COMPANY
  17. Using the special tools, install the front output shaft bearing. Use Special Service Tool: 307-181 (T87C-77000-D) Installer, Transaxle Bearing Cone., 205-090 (T75L-1165-B) Plate, Bearing/Oil Seal.. Use the General Equipment: Hydraulic Press
    GFD626667Courtesy of FORD MOTOR COMPANY
  18. NOTE: Install the drive chain and sprockets as an assembly.

    Install the drive chain and sprockets.

    GFD626639Courtesy of FORD MOTOR COMPANY
  19. NOTE: Set the 2-4 shift rod assembly pin into the groove of the control shift rod.

    Install the shift rod.

    GFD626638Courtesy of FORD MOTOR COMPANY
  20. Install the shift fork and install the shift fork snap ring.
    GFD626668Courtesy of FORD MOTOR COMPANY
  21. Install the transfer case synchronizer strut.
    GFD626636Courtesy of FORD MOTOR COMPANY
  22. Install the transfer case synchronizer circlip.
    GFD626669Courtesy of FORD MOTOR COMPANY
  23. Install the transfer case synchronizer.
    GFD626634Courtesy of FORD MOTOR COMPANY
  24. Install the lock hab and lock hab circlip.
    GFD626670Courtesy of FORD MOTOR COMPANY
  25. NOTE: Make sure the oil pump is installed in the range of the rib.

    Install the oil pump.

    GFD626632Courtesy of FORD MOTOR COMPANY
  26. Using the special tools, install the rear output shaft bearing. Use Special Service Tool: 308-410 Installer, Output Shaft Front Bearing., 205-153 (T80T-4000-W) Handle.
    GFD626671Courtesy of FORD MOTOR COMPANY
  27. Install the rear output shaft bearing circlip.
    GFD626672Courtesy of FORD MOTOR COMPANY
  28. Install the dowel pins.
    GFD626629Courtesy of FORD MOTOR COMPANY
  29. NOTE: Only apply enough silicone sealant to seal the transfer case halves together and does not squeeze into the transfer case.

    Apply a small bead of silicone sealant to the mating surface of the case half.

    Material: Motorcraft® Ultra Silicone Sealant / TA-29 (WSS-M4G323-A8)

    GFD626673Courtesy of FORD MOTOR COMPANY
  30. Position the transfer case halves
    GFD626674Courtesy of FORD MOTOR COMPANY
  31. tighten the transfer case bolts.

    Torque: 33 lb.ft (45 Nm)

    Fig 1: Transfer Case Bolts Tightening Sequence
    GFD626675Courtesy of FORD MOTOR COMPANY
  32. Using the special tools, install the input shaft seal. Use Special Service Tool: 308-614 Installer, Output Shaft Seal.
    GFD626956Courtesy of FORD MOTOR COMPANY
  33. Using the special tool, install the rear output shaft seal. Use Special Service Tool: 205-199 (T83T-3132-A1) Installer, Spindle/Axle Shaft., 308-976 Installer, Output Shaft Seal.
    GFD626614Courtesy of FORD MOTOR COMPANY
  34. NOTE: Make sure output flange and output shaft are phased correctly using previously applied mark.

    Install the rear output flange.

    GFD626677Courtesy of FORD MOTOR COMPANY
  35. Install the new output shaft flange nut. Use Special Service Tool: 205-153 (T80T-4000-W) Handle.

    Torque: 275 lb.ft (373 Nm)

    GFD626678Courtesy of FORD MOTOR COMPANY
  36. Using the special tool, install the front output shaft seal. Use Special Service Tool: 308-430 Installer, PTO Drive Gear Outer Oil Seal., 308-431 Installer, Halfshaft Oil Seal.
    GFD626600Courtesy of FORD MOTOR COMPANY
  37. NOTE: Make sure output flange and output shaft are phased correctly using previously applied mark.

    Install the front output flange.

    GFD626601Courtesy of FORD MOTOR COMPANY
  38. Install the new output shaft flange nut. Use Special Service Tool: 205-126 (T78P-4851-A) Holding Fixture, Drive Pinion Flange.

    Torque: 203 lb.ft (275 Nm)

    GFD626602Courtesy of FORD MOTOR COMPANY
  39. NOTE: Make sure a new O-ring is installed.
    NOTE: Lubricate the O-ring before installing.

    Install the O-ring seal on the transfer case shift motor.

    GFD626577Courtesy of FORD MOTOR COMPANY
  40. NOTE: X : 5.4 deg.

    Align the transfer case electric shift cam control lever to X: 5.4 deg.

    GFD626578Courtesy of FORD MOTOR COMPANY
  41. Remove the transfer case from the transmission adjustable mounting arms.. Use the General Equipment: Adjustable Mounting Arm
GFD626623Courtesy of FORD MOTOR COMPANY
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