Transfer Case Front Output Shaft Seal

WARNING: This page is about a different car, the 2017 Lincoln Navigator and 2017 Ford Expedition. However, it is still accessible from the selected car via links, so may be relevant.

Special Tool(s)

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

Material

Item	Specification
Motorcraft ® MERCON ® LV Automatic Transmission FluidXT-10-QLVC (US); CXT-10-LV12 (Canada)	MERCON ® LV
Ultra Silicone Sealant TA-29	-

1.

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

2.

Clean the mating surfaces of the cases.

3.

Using the Input Shaft Oil Seal Installer, install a new front output shaft seal.

GFD136514

Courtesy of FORD MOTOR COMPANY

4.

Install the front output shaft and the snap ring.

GFD136507

Courtesy of FORD MOTOR COMPANY

5.

Install the driven sprocket spacer.

GFD136568

Courtesy of FORD MOTOR COMPANY

6.

Install the drive chain and the sprockets as an assembly.

GFD136534

Courtesy of FORD MOTOR COMPANY

7.

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.

Install the clutch pack assembly with the armature.

GFD136533

Courtesy of FORD MOTOR COMPANY

8.

Install the new snap ring.

GFD136517

Courtesy of FORD MOTOR COMPANY

9.

Install the wave spring.

GFD136498

Courtesy of FORD MOTOR COMPANY

10.

Install the cam and the 3 steel balls.

GFD136532

Courtesy of FORD MOTOR COMPANY

11.

Install the cam/coil housing.

GFD136531

Courtesy of FORD MOTOR COMPANY

12.

Install the thrust bearing assembly.

GFD136495

Courtesy of FORD MOTOR COMPANY

13.

Install the spacer.

GFD136494

Courtesy of FORD MOTOR COMPANY

14.

Install the snap ring.

GFD136493

Courtesy of FORD MOTOR COMPANY

15.

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).

GFD136489

Courtesy of FORD MOTOR COMPANY

16.

Install the 3 coil washers and nuts.
- Tighten to 10 Nm (89 lb-in).

17.

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.

18.

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.

GFD136574

Courtesy of FORD MOTOR COMPANY

19.

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

Insert the coil wire pin in the electrical connector and install the inner connector retainer.

GFD136527

Courtesy of FORD MOTOR COMPANY

20.

Secure the transfer case to a transmission jack and remove the transfer case from the Transmission Holding Fixture.

GFD136515

Courtesy of FORD MOTOR COMPANY

21.

Install the transfer case. For additional information, refer to Transfer Case .