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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 2015 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.

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.

GFD42018

Courtesy of FORD MOTOR COMPANY

2.

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.

GFD41976

Courtesy of FORD MOTOR COMPANY

3.

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.

GFD42019

Courtesy of FORD MOTOR COMPANY

4.

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.

GFD42020

Courtesy of FORD MOTOR COMPANY

5.

Using the special tool, install the input shaft seal.
Use Special Service Tool: 308-250 (T96T-7127-B) Installer, Output Shaft Oil Seal.

GFD42021

Courtesy of FORD MOTOR COMPANY

6.

Using the special tool, install the front output shaft seal.
Use Special Service Tool: 308-250 (T96T-7127-B) Installer, Output Shaft Oil Seal.

GFD41977

Courtesy of FORD MOTOR COMPANY

7.

NOTE: Do not let the front output shaft fall while removing the snap ring or damage to the component may occur.

Install the output shaft and the out put shaft circlip.

GFD41973

Courtesy of FORD MOTOR COMPANY

8.

Install the ring gear.

GFD42013

Courtesy of FORD MOTOR COMPANY

9.

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.

10.

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

Install the front planet carrier.

GFD42012

Courtesy of FORD MOTOR COMPANY

11.

Install the ring gear circlip.

GFD42011

Courtesy of FORD MOTOR COMPANY

12.

Install the planet carrier thrust bearing.

GFD42010

Courtesy of FORD MOTOR COMPANY

13.

Install the electric shift cam assembly.

GFD42009

Courtesy of FORD MOTOR COMPANY

14.

Install the reduction hub.

GFD42008

Courtesy of FORD MOTOR COMPANY

15.

Install the output shaft.

GFD42007

Courtesy of FORD MOTOR COMPANY

16.

Install the shift fork.

GFD42006

Courtesy of FORD MOTOR COMPANY

17.

Install the shift rail.

GFD42005

Courtesy of FORD MOTOR COMPANY

18.

Install the oil pump assembly.

GFD42004

Courtesy of FORD MOTOR COMPANY

19.

Install the magnet into its slot in the case.

GFD42003

Courtesy of FORD MOTOR COMPANY

20.

Install the thrust bearing assembly.
- Install the thrust washer.
- Install the thrust bearing.
- Install the thrust washer.

GFD42002

Courtesy of FORD MOTOR COMPANY

21.

Install the output shaft sprocket spacer.

GFD41972

Courtesy of FORD MOTOR COMPANY

22.

Install the drive chain and the sprockets as an assembly.

GFD41971

Courtesy of FORD MOTOR COMPANY

23.

Install the clutch pack spacer.

GFD42001

Courtesy of FORD MOTOR COMPANY

24.

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.

GFD41970

Courtesy of FORD MOTOR COMPANY

25.

Install the clutch pack circlip.

GFD41969

Courtesy of FORD MOTOR COMPANY

26.

Install the wave spring.

GFD41968

Courtesy of FORD MOTOR COMPANY

27.

Install the cam and the steel balls.

GFD41967

Courtesy of FORD MOTOR COMPANY

28.

Install the coil housing.

GFD41966

Courtesy of FORD MOTOR COMPANY

29.

Install the coil housing thrust bearing assembly.

GFD41965

Courtesy of FORD MOTOR COMPANY

30.

Install the coil housing spacer and snap ring.

GFD41964

Courtesy of FORD MOTOR COMPANY

31.

Install the transfer case field coil.

GFD41963

Courtesy of FORD MOTOR COMPANY

32.

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

: Ultra Silicone Sealant / TA-29

GFD41978

Courtesy of FORD MOTOR COMPANY

33.

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

: 21 lb.ft (29 Nm)

GFD41979

Courtesy of FORD MOTOR COMPANY

34.

Install the coil washers and nuts.
Torque

: 89 lb.in (10 Nm)

GFD41960

Courtesy of FORD MOTOR COMPANY

35.

Install the transfer case rear seal. Refer to: Transfer Case Rear Seal .

36.

Apply a small bead of silicone sealant to the transfer case shift motor mating surface.
Material

: Ultra Silicone Sealant / TA-29

GFD41948

Courtesy of FORD MOTOR COMPANY

37.

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)

GFD41980

Courtesy of FORD MOTOR COMPANY

38.

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.

GFD41950

Courtesy of FORD MOTOR COMPANY

39.

Remove the transfer case from the transmission adjustable mounting arms.
Use the General Equipment: Adjustable Mounting Arm

GFD41958

Courtesy of FORD MOTOR COMPANY