Transfer Case - Vehicles With: 2-Speed Torque On Demand Transfer Case: Assembly

WARNING: This page is about a different car, the 2020 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Lubricate all internal components with the recommended transfer case lubricant during reassembly.

Using the special tools, install the front planet carrier bearing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 205-504 Installer, Halfshaft Pilot Bearing.

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Using the special tools, install the front output shaft bearing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 205-293 (T89P-4850-A) Installer, Differential Oil Seal.

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Using the special tool, install the front output shaft support bearing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 307-582A Cover Axle Seal Installer.

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Using the special tool, install the rear output shaft bearing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 307-582A Cover Axle Seal Installer.

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Using the special tool, install the input shaft seal. Use Special Service Tool: 308-250 (T96T-7127-B) Installer, Output Shaft Oil Seal.

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Using the special tool, install the front output shaft seal. Use Special Service Tool: 308-250 (T96T-7127-B) Installer, Output Shaft Oil Seal.

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NOTE: Do not let the front output shaft fall while removing the snap ring or damage to the component may occur.

Install the output shaft and the out put shaft circlip.

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Install the ring gear.

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If removed, using a press and the special tool, install the needle bearing into the front planet carrier. Use Special Service Tool: 308-085 (T83T-7025-C) Installer, Input Shaft Bearing.
NOTE: Replace the inner planet carrier needle bearing if necessary.

Install the front planet carrier.

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Install the ring gear circlip.

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Install the planet carrier thrust bearing.

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Install the electric shift cam assembly.

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Install the reduction hub.

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Install the output shaft.

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Install the shift fork.

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Install the shift rail.

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Install the oil pump assembly.

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Install the magnet into its slot in the case.

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Install the thrust bearing assembly.
- Install the thrust washer.
- Install the thrust bearing.
- Install the thrust washer.
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Install the output shaft sprocket spacer.

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Install the drive chain and the sprockets as an assembly.

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Install the clutch pack spacer.

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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.

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Install the clutch pack circlip.

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Install the wave spring.

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Install the cam and the steel balls.

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Install the coil housing.

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Install the coil housing thrust bearing assembly.

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Install the coil housing spacer and snap ring.

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Install the transfer case field coil.

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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

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NOTE: Position the field coil bolts to align with the field coil bolt holes in the rear case. Position field coil wire through the field coil wire through hole in the case.

Position the transfer case halves and tighten the bolts in the sequence shown.

Torque: 21 lb.ft (29 Nm)

Fig 1: Transfer Case Tightening Sequence (Vehicles With: 2-Speed Torque On Demand Transfer Case)
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Install the coil washers and nuts.
Torque: 89 lb.in (10 Nm)

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Install the transfer case rear seal. Refer to: Transfer Case Rear Seal .
Apply a small bead of silicone sealant to the transfer case shift motor mating surface.
Material: Motorcraft® Ultra Silicone Sealant / TA-29

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NOTE: When installing the shift motor, tighten the bracket nuts last. Failure to follow the steps in the correct order may result in damage to the component.
1. Install the transfer case shift motor.
2. Install the transfer case shift motor bolts.
  Torque: 89 lb.in (10 Nm)
3. Install the transfer case shift motor bracket bolt.
  Torque: 89 lb.in (10 Nm)
4. Tighten the transfer case shift motor bracket nuts.
  Torque: 27 lb.in (3 Nm)
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NOTE: After the coil wire is inserted into the connector, gently pull the wire back to verify the pin is locked inside the connector.

Install the coil wire pin in the electrical connector.
1. Insert the coil wire pin in the electrical connector.
2. Install the inner connector retainer.
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Remove the transfer case from the transmission adjustable mounting arms. Use the General Equipment: Adjustable Mounting Arm

GFD464824

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