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

WARNING: This page is about a different car, the 2021 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.
  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

    GFD559928Courtesy of FORD MOTOR COMPANY
  2. Clean the transfer case housing and cover flange sealing surfaces. Refer to: RTV Sealing Surface Cleaning and Preparation .
    GFD559929Courtesy of FORD MOTOR COMPANY
  3. Using the special tools, install the shift shaft seal.

    Use Special Service Tool: 307-549 Installer, Shift Shaft Fluid Seal.

    GFD559930Courtesy of FORD MOTOR COMPANY
  4. 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.

    GFD559931Courtesy of FORD MOTOR COMPANY
  5. 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.

    GFD559932Courtesy of FORD MOTOR COMPANY
  6. 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.

    GFD559933Courtesy of FORD MOTOR COMPANY
  7. 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.

    GFD559934Courtesy of FORD MOTOR COMPANY
  8. Using the special tool, install the front output shaft seal.

    Use Special Service Tool: 308-250 (T96T-7127-B) Installer, Output Shaft Oil Seal.

    GFD559935Courtesy of FORD MOTOR COMPANY
  9. Using the special tool, install the input shaft seal.

    Use Special Service Tool: 308-250 (T96T-7127-B) Installer, Output Shaft Oil Seal.

    GFD559936Courtesy of FORD MOTOR COMPANY
  10. Install the front output shaft.
    GFD559920Courtesy of FORD MOTOR COMPANY
  11. Install the front output shaft dust cover.
    GFD559919Courtesy of FORD MOTOR COMPANY
  12. Install the ring gear.
    GFD559918Courtesy of FORD MOTOR COMPANY
  13. 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.

  14. NOTE: Replace the inner planet carrier needle bearing if necessary.

    Install the front planet carrier.

    GFD559917Courtesy of FORD MOTOR COMPANY
  15. Install the ring gear circlip.
    GFD559916Courtesy of FORD MOTOR COMPANY
  16. Install the planet carrier thrust bearing.
    GFD559915Courtesy of FORD MOTOR COMPANY
  17. Install the electric shift cam assembly.
    GFD559914Courtesy of FORD MOTOR COMPANY
  18. Install the reduction hub.
    GFD559962Courtesy of FORD MOTOR COMPANY
  19. Install the output shaft.
    GFD559961Courtesy of FORD MOTOR COMPANY
  20. Install the shift fork.
    GFD559960Courtesy of FORD MOTOR COMPANY
  21. Install the shift rail.
    GFD559959Courtesy of FORD MOTOR COMPANY
  22. Install the oil pump assembly.
    GFD559958Courtesy of FORD MOTOR COMPANY
  23. Install the magnet into its slot in the case.
    GFD559957Courtesy of FORD MOTOR COMPANY
  24. Install the thrust bearing assembly.

    • Install the thrust washer.

    • Install the thrust bearing.

    • Install the thrust washer.

    GFD559956Courtesy of FORD MOTOR COMPANY
  25. Install the drive chain and the sprockets as an assembly.
    GFD559955Courtesy of FORD MOTOR COMPANY
  26. Install the output shaft sprocket spacer.
    GFD559954Courtesy of FORD MOTOR COMPANY
  27. Install the clutch pack spacer.
    GFD559953Courtesy of FORD MOTOR COMPANY
  28. 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.

    GFD559952Courtesy of FORD MOTOR COMPANY
  29. Install the clutch pack circlip.
    GFD559951Courtesy of FORD MOTOR COMPANY
  30. Install the wave spring.
    GFD559950Courtesy of FORD MOTOR COMPANY
  31. Install the cam and the steel balls.
    GFD559949Courtesy of FORD MOTOR COMPANY
  32. Install the coil housing.
    GFD559948Courtesy of FORD MOTOR COMPANY
  33. Install the coil housing thrust bearing assembly.
    GFD559947Courtesy of FORD MOTOR COMPANY
  34. Install the coil housing spacer and snap ring.
    GFD559946Courtesy of FORD MOTOR COMPANY
  35. Install the transfer case field coil.
    GFD559945Courtesy of FORD MOTOR COMPANY
  36. If dowel pin is damaged install new dowel pin.
    GFD559944Courtesy of FORD MOTOR COMPANY
  37. 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)

    GFD559937Courtesy of FORD MOTOR COMPANY
  38. 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 in illustration.

    Torque

    : 18 lb.ft (24 Nm)

    GFD559938Courtesy of FORD MOTOR COMPANY
  39. Install the transfer case field coil washers and the nuts.

    Torque

    : 89 lb.in (10 Nm)

    GFD559897Courtesy of FORD MOTOR COMPANY
  40. Clean the transfer case shift motor mating surface.
    GFD559939Courtesy of FORD MOTOR COMPANY
  41. Apply a small bead of silicone sealant to the transfer case shift motor mating surface.

    Material

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

    GFD559940Courtesy of FORD MOTOR COMPANY
  42. 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)

    GFD559941Courtesy of FORD MOTOR COMPANY
  43. 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.

    GFD559863Courtesy of FORD MOTOR COMPANY
  44. Using the special tool, install the rear output shaft seal.

    Use Special Service Tool: 308-249 (T96T-7127-A) Installer, Input Shaft Oil Seal.

    GFD559942Courtesy of FORD MOTOR COMPANY
  45. Install the vibration damper to the transfer case.

    Torque

    : 177 lb.in (20 Nm)

    GFD559895Courtesy of FORD MOTOR COMPANY
  46. Remove the transfer case from the transmission adjustable mounting arms.

    Use the General Equipment: Adjustable Mounting Arm

GFD559893Courtesy of FORD MOTOR COMPANY
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