Transfer Case Front Output Shaft Seal - Vehicles With: Electronic Shift Transfer Case: Installation

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.

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

Courtesy of FORD MOTOR COMPANY
Clean the transfer case housing and cover flange sealing surfaces. Refer to: RTV Sealing Surface Cleaning and Preparation .

Courtesy of FORD MOTOR COMPANY
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.

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

Courtesy of FORD MOTOR COMPANY
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 output shaft circlip.

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

Install the drive chain and sprockets.

Courtesy of FORD MOTOR COMPANY
Install the lock up hub, shift fork and shift fork spring.

Courtesy of FORD MOTOR COMPANY
Install the field coil housing.

Courtesy of FORD MOTOR COMPANY
Install the field coil housing snap ring.

Courtesy of FORD MOTOR COMPANY
Install the transfer case field coil.

Courtesy of FORD MOTOR COMPANY
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

Courtesy of FORD MOTOR COMPANY
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: 18 lb.ft (24 Nm)

Courtesy of FORD MOTOR COMPANY
Install the transfer case field coil washers and the nuts.
Torque: 89 lb.in (10 Nm)

Courtesy of FORD MOTOR COMPANY
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

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

Courtesy of FORD MOTOR COMPANY
Install the transfer case. Refer to: Transfer Case .