Transfer Case Front Output Shaft Seal

WARNING: This page is about a different variant/trim than selected.

SPECIAL TOOLS CHART

	Holding Fixture, Transmission 307-003 (T57L-500-B)
	Installer, Input Shaft Oil Seal 308-249 (T96T-7127-A)

MATERIAL SPECIFICATIONS

Item	Specification
Motorcraft® MERCON® LV Automatic Transmission Fluid XT-10-QLVC	MERCON® LV
Ultra Silicone Sealant TA-29	-

Lubricate all internal components with the recommended transfer case lubricant during reassembly.
Clean the mating surfaces of the cases.
Using the Input Shaft Oil Seal Installer, install a new front output shaft seal.

Fig 1: Installing Front Output Shaft Seal
Courtesy of FORD MOTOR CO.
Install the front output shaft and the snap ring.

Fig 2: Locating Snap Ring And Front Output Shaft
Courtesy of FORD MOTOR CO.
Install the driven sprocket spacer.

Fig 3: Locating Driven Sprocket Spacer
Courtesy of FORD MOTOR CO.
Install the drive chain and the sprockets as an assembly.

Fig 4: Locating Drive Chain And Sprockets Assembly
Courtesy of FORD MOTOR CO.

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 must be installed and the armature transferred. Failure to install a new clutch pack can result in component failure.

Fig 5: Locating Clutch Pack Assembly

Courtesy of FORD MOTOR CO.

Install the clutch pack assembly with the armature.
Install the new snap ring.

Fig 6: Locating Snap Ring
Courtesy of FORD MOTOR CO.
Install the wave spring.

Fig 7: Locating Wave Spring
Courtesy of FORD MOTOR CO.
Install the cam and the 3 steel balls.

Fig 8: Locating Steel Balls And Cam
Courtesy of FORD MOTOR CO.
Install the cam/coil housing.

Fig 9: Locating Cam/Coil Housing
Courtesy of FORD MOTOR CO.
Install the thrust bearing assembly.

Fig 10: Locating Thrust Bearing Assembly
Courtesy of FORD MOTOR CO.
Install the spacer.

Fig 11: Locating Spacer
Courtesy of FORD MOTOR CO.
Install the snap ring.

Fig 12: Locating Snap Ring
Courtesy of FORD MOTOR CO.

NOTE: Only apply enough silicone sealant to seal the transfer case halves together.

Apply a bead of silicone sealant to the transfer case mating surface, then position the 2 transfer case halves together. Tighten the 20 transfer case bolts evenly in a star pattern.
- Position the coil studs through the case holes, making sure the shift cam shaft is aligned with its case bore and the lockup shift fork spring is in position.
- Tighten to 29 Nm (21 lb-ft).
  
  Fig 13: Locating Transfer Case Bolt
  Courtesy of FORD MOTOR CO.
Install the 3 coil washers and nuts.
- Tighten to 10 Nm (89 lb-in).
Apply a small bead of silicone sealant to the transfer case shift motor mating surface.
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.
Install the transfer case shift motor.
1. Install the 3 transfer case shift motor bolts.
  - Tighten to 10 Nm (89 lb-in).
2. Install the transfer case shift motor bracket bolt.
  - Tighten to 10 Nm (89 lb-in).
3. Secure the transfer case shift motor bracket nuts.
  
  Fig 14: Identifying Transfer Case Shift Motor Bracket Nuts
  Courtesy of FORD MOTOR CO.

NOTE: After the wire is inserted into the connector, gently pull the wire back to verify the pin is locked inside the connector.

Fig 15: Locating Coil Wire Pin In Electrical Connector

Courtesy of FORD MOTOR CO.

Insert the coil wire pin in the electrical connector and install the inner connector retainer.
Secure the transfer case to a transmission jack and remove the transfer case from the Transmission Holding Fixture.

Fig 16: Removing Transfer Case From Transmission Holding Fixture
Courtesy of FORD MOTOR CO.
Install the transfer case. For additional information, refer to TRANSFER CASE .