Transfer Case - Vehicles With: Electronic Shift 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.

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.

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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.

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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.

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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.

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5.

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

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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.

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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.

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8.

Install the ring gear.

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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.

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11.

Install the ring gear circlip.

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12.

Install the planet carrier thrust bearing.

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13.

Install the electric shift cam assembly.

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14.

Install the reduction hub.

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15.

Install the output shaft.

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16.

Install the shift fork.

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17.

Install the shift rail.

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18.

Install the oil pump assembly.

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19.

Install the magnet into its slot in the case.

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20.

Install the sprocket thrust washer.

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21.

NOTE: Install the drive chain and sprockets as an assembly.

Install the drive chain and sprockets.

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22.

Install the lock up hub, shift fork and shift fork spring.

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23.

Install the field coil housing.

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24.

Install the field coil housing snap ring.

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25.

Install the transfer case field coil.

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26.

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

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27.

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

: 18 lb.ft (24 Nm)

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28.

Install the transfer case field coil washers and the nuts.
Torque

: 89 lb.in (10 Nm)

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29.

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

30.

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

: Ultra Silicone Sealant / TA-29

Courtesy of FORD MOTOR COMPANY

31.

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)

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32.

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.

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33.

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

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