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Transfer Case: Assembly

WARNING: This page is about a different variant/trim than selected.
  1. Lubricate all internal components with the recommended transfer case lubricant during reassembly.
  2. Clean the mating surfaces of the cases.
  3. Using a suitable press and the special tools, install the front planet support bearing.
    Fig 1: Installing Front Planet Support Bearing
    G04629011Courtesy of FORD MOTOR CO.
  4. Using a suitable press and the special tools, install the front output shaft support bearing.
    Fig 2: Installing Front Output Shaft Support Bearing
    G04629012Courtesy of FORD MOTOR CO.
  5. Using the special tool, install a new oil seal.
    Fig 3: Installing New Oil Seal
    G04629013Courtesy of FORD MOTOR CO.
    6. CAUTION: Be careful not to crush the seal.
    Fig 4: Identifying Shifter Shaft Seal
    G04629014Courtesy of FORD MOTOR CO.
  6. Using the special tool, install a new shifter shaft seal.
  7. Install the case to the transmission holding fixture. Secure the case to the work bench.
  8. Using special tool 308-249, install a new oil seal.
  9. Install the ring gear.
    1. Position the ring gear in the case.
    2. Install the snap ring.
      Fig 5: Identifying Position Of Ring Gear & Snap Ring In Case
      G04629015Courtesy of FORD MOTOR CO.
  10. Install the front output shaft and the snap ring.
    11. NOTE: If removed, using a suitable press and the special tool 308-085, install the needle bearing into the front planet. Be careful not to crush the bearing cage.
    Fig 6: Locating Front Planet
    G04629016Courtesy of FORD MOTOR CO.
  11. Install the front planet.
  12. Install the shift fork shaft.
    Fig 7: Locating Shift Fork Shaft
    G04629017Courtesy of FORD MOTOR CO.
    13. NOTE: Assemble the reduction hub and the reduction shift fork.
    Fig 8: Locating Reduction Hub & Reduction Shift Fork
    G04629018Courtesy of FORD MOTOR CO.
  13. Install the reduction shift fork, the reduction hub and the shift cam as an assembly.
  14. Install the output shaft.
    Fig 9: Locating Output Shaft
    G04629019Courtesy of FORD MOTOR CO.
  15. Install the oil pump assembly.
    • Make sure the oil pump finger is in the slot in the case.
      Fig 10: Identifying Oil Pump Finger
      G04629020Courtesy of FORD MOTOR CO.
  16. Install the oil pan magnet into its slot in the case.
    Fig 11: Installing Oil Pan Magnet Into Its Slot
    G04629021Courtesy of FORD MOTOR CO.
  17. Install the output shaft sprocket.
    Fig 12: Locating Output Shaft Sprocket
    G04629022Courtesy of FORD MOTOR CO.
  18. Install the 3-piece thrust bearing assembly.
    1. Install the thrust washer.
    2. Install the thrust bearing.
    3. Install the thrust washer.
      Fig 13: Identifying 3-Piece Thrust Bearing Assembly
      G04629023Courtesy of FORD MOTOR CO.
  19. Install the drive chain and the sprockets as an assembly.
    Fig 14: Locating Drive Chain & Sprockets Assembly
    G04629024Courtesy of FORD MOTOR CO.
    20. CAUTION: 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 can occur.
    Fig 15: Locating Clutch Pack Assembly
    G04629025Courtesy of FORD MOTOR CO.
  20. Install the clutch pack assembly.
  21. Install a new snap ring.
    Fig 16: Locating Snap Ring
    G04629026Courtesy of FORD MOTOR CO.
  22. Install the wave spring.
  23. Install the cam and the steel balls.
    Fig 17: Locating Cam & Steel Balls
    G04629027Courtesy of FORD MOTOR CO.
  24. Install the cam/coil housing.
    Fig 18: Locating Cam/Coil Housing
    G04629028Courtesy of FORD MOTOR CO.
  25. Install the thrust bearing assembly.
  26. Install the snap ring.
  27. Using a suitable press and the special tool, install the rear output shaft support bearing.
    Fig 19: Locating Rear Output Shaft Support Bearing
    G04629029Courtesy of FORD MOTOR CO.
  28. Using a suitable press and the special tool, install the front output shaft rear bearing.
    Fig 20: Locating Front Output Shaft Rear Bearing
    G04629030Courtesy of FORD MOTOR CO.
    29. CAUTION: Applying too much silicone sealant can plug the fluid filter and cause transfer case failure.
  29. Apply a bead of silicone sealant to the transfer case mating surfaces, then position the 2 transfer case halves together. Tighten the transfer case bolts evenly in a star pattern.
    • Position the coil studs through the case holes, make sure the shift cam shaft is aligned with its case bore, and the lockup shift fork spring is in position.
    • Tighten to 24 N.m (18 lb-ft).
      Fig 21: Locating Coil Studs
      G04629031Courtesy of FORD MOTOR CO.
  30. Install the 3 coil washers and nuts.
    • Tighten to 10 N.m (89 lb-in).
  31. Using the special tool, install the oil seal.
    Fig 22: Identifying Special Tool
    G04629032Courtesy of FORD MOTOR CO.
  32. Install the transfer case shift motor.
    • Tighten the shift motor bolts to 10 N.m (89 lb-in).
  33. Install the coil wire pin in the electrical connector.
    • Remove the wire connector spacer.
    • Install the coil wire pin. Reinstall the wire connector spacer.
  34. Remove the transfer case from the special tool.
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