Transfer Case - Electronic Shift: Assembly

WARNING: This page is about a different car, the 2013 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.

Using a press and the Bearing Cup Installer with the Handle, install the front output shaft bearing.

Fig 1: Installing Front Output Shaft Bearing Using Press And Bearing Cup Installer With Handle
Courtesy of FORD MOTOR CO.
Using the Input Shaft Oil Seal Installer, install the front output shaft seal.

Fig 2: Installing Front Output Shaft Seal Using Input Shaft Oil Seal Installer
Courtesy of FORD MOTOR CO.
Install the front output shaft.
1. Position the front output shaft.
2. Install the front output shaft snap ring.
  
  Fig 3: Installing Front Output Shaft And Snap Ring
  Courtesy of FORD MOTOR CO.
Install the driven sprocket spacer.

Fig 4: Locating Driven Sprocket Spacer
Courtesy of FORD MOTOR CO.
Install the front planet carrier bearing.

Fig 5: Installing Front Planet Carrier Bearing
Courtesy of FORD MOTOR CO.
Using the Input Shaft Oil Seal Installer, install the front input seal.

Fig 6: Installing Front Input Shaft Seal Using Input Shaft Oil Seal Installer
Courtesy of FORD MOTOR CO.
Position the ring gear in the case. Install the ring gear snap ring.
If removed, using a press and the Input Shaft Bearing Installer, install the needle bearing into the front planet carrier.

Fig 7: Installing Needle Bearing Using Special Tool
Courtesy of FORD MOTOR CO.
Install the front planet carrier and the thrust bearing.

Fig 8: Locating Front Planet Carrier
Courtesy of FORD MOTOR CO.
Install the electric shift cam assembly.

Fig 9: Installing Electric Shift Cam Assembly
Courtesy of FORD MOTOR CO.
Install the shift fork and the reduction hub.

Fig 10: Locating Shift Fork And Reduction Hub
Courtesy of FORD MOTOR CO.
Install the shift rail.

Fig 11: Installing Shift Rail
Courtesy of FORD MOTOR CO.
Install the oil pump, output shaft and the thrust washer.

Fig 12: Installing Oil Pump, Output Shaft And Thrust Washer
Courtesy of FORD MOTOR CO.
Install the magnet into its slot in the case.

Fig 13: Installing Magnet
Courtesy of FORD MOTOR CO.
Install the drive chain and the sprockets as an assembly.

Fig 14: Installing Drive Chain And Sprocket Assembly
Courtesy of FORD MOTOR CO.
Install the lockup hub assembly. If the lockup hub assembly was disassembled, carry out the following steps.
1. Position the lockup collar.
2. Install the lockup collar springs.
3. Install the lockup hub.
4. Install the armature.
5. Install the lockup hub snap ring.
  
  Fig 15: Assembling Lockup Hub Assembly
  Courtesy of FORD MOTOR CO.
Install the lockup hub and the shift fork and spring.

Fig 16: Locating Lockup Hub And Spring
Courtesy of FORD MOTOR CO.
Install the coil housing.

Fig 17: Installing Coil Housing
Courtesy of FORD MOTOR CO.
Install the snap ring.

Fig 18: Locating Snap Ring
Courtesy of FORD MOTOR CO.
Using the Mainshaft Bearing Installer, install the rear output shaft bearing.

Fig 19: Installing Rear Output Shaft Bearing Using Mainshaft Bearing Installer
Courtesy of FORD MOTOR CO.
Using the Mainshaft Bearing Installer, install the front output shaft bearing.

Fig 20: Installing Front Output Shaft Bearing Using Mainshaft Bearing Installer
Courtesy of FORD MOTOR CO.
Install the transfer case field coil, washers and the 3 nuts.
- Tighten to 10 Nm (89 lb-in).
Fig 21: Locating Transfer Case Field Coil Nuts And Washers
Courtesy of FORD MOTOR CO.
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 and cover.
Position the 2 transfer case halves and tighten the 20 bolts in the sequence shown in illustration.
- Tighten to 24 Nm (18 lb-ft).
  
  Fig 22: Identifying Transfer Case Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Using the Input Shaft Oil Seal Installer, install the rear output shaft seal.

Fig 23: Installing Rear Output Shaft Seal Using Input Shaft Oil Seal Installer
Courtesy of FORD MOTOR CO.
Apply a small bead of silicone sealant to the transfer case shift motor mating surface.
NOTE: The following steps need to be performed in the correct order when installing the transfer case shift motor. Failure to follow the steps in the correct order may result in damage to the component.
Install the transfer case shift motor and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 24: Installing Transfer Case Shift Motor Bolts
  Courtesy of FORD MOTOR CO.
Install the transfer case shift motor bracket bolt.
- Tighten to 10 Nm (89 lb-in).
Secure the 2 transfer case shift motor bracket nuts.
- Tighten to 3 Nm (27 lb-in).
NOTE: After the coil 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.

Fig 25: Locating Coil Wire Pin In Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the transfer case from the Transmission Holding Fixture.

Fig 26: Removing Transfer Case From Transmission Holding Fixture
Courtesy of FORD MOTOR CO.