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Home >> Ford >> 2022 >> Bronco Raptor >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 32 (Transfer Case - Advanced 4X4 With 4A Mode - Manual) >> Removal And Installation >> Transfer Case Clutch >> Installation

Transfer Case Clutch: Installation

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. Use the General Equipment: Spatula
    GFD626708Courtesy of FORD MOTOR COMPANY
  2. Clean the transfer case housing and cover flange sealing surfaces. Refer to: RTV Sealing Surface Cleaning and Preparation .
    GFD626709Courtesy of FORD MOTOR COMPANY
  3. NOTE: When installing the clutch assembly, do not separate the clutch pack assembly. The thrust washer in the lower clutch pack uses tabs to hold it in place. If the thrust washer is not in place, a transfer case clearance problem will occur.
    NOTE: If the clutch pack is disassembled, a new clutch pack and armature must be installed. Failure to install a new clutch pack can result in component failure.

    Install the clutch pack assembly with the armature.

    GFD626707Courtesy of FORD MOTOR COMPANY
  4. NOTE: Install the drive chain and sprockets as an assembly.

    Install the drive chain and sprockets

    GFD626706Courtesy of FORD MOTOR COMPANY
  5. Install the thrust washer.
    GFD626705Courtesy of FORD MOTOR COMPANY
  6. Install the thrust bearing.
    GFD626704Courtesy of FORD MOTOR COMPANY
  7. Install the thrust washer.
    GFD626703Courtesy of FORD MOTOR COMPANY
  8. Install the snap ring.
    GFD626702Courtesy of FORD MOTOR COMPANY
  9. Install the magnet to its slot in the case.
    GFD626701Courtesy of FORD MOTOR COMPANY
  10. Install the transfer case dowel pins.
    GFD626700Courtesy of FORD MOTOR COMPANY
  11. Install the transfer case dowel pins.
    GFD626700Courtesy of FORD MOTOR COMPANY
  12. NOTE: Only apply enough silicone sealant to seal the transfer case halves together.

    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)

    GFD626710Courtesy of FORD MOTOR COMPANY
  13. Position the transfer case halves and tighten the bolts in the sequence shown.

    Torque: 21 lb.ft (29 Nm)

    Fig 1: Transfer Case Bolts Tightening Sequence
    GFD626711Courtesy of FORD MOTOR COMPANY
  14. Install the wiring harness and retainers.

    Torque: 89 lb.in (10 Nm)

    GFD626697Courtesy of FORD MOTOR COMPANY
  15. Connect the electrical connector and wiring harness retainer.
    GFD626581Courtesy of FORD MOTOR COMPANY
  16. Install the transfer case rear seal. Refer to: Transfer Case Rear Seal .
  17. Remove the transfer case from the transmission adjustable mounting arms. Use the General Equipment: Adjustable Mounting Arm
    GFD626696Courtesy of FORD MOTOR COMPANY
  18. Install the transfer case. Refer to: Transfer Case .
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