Transfer Case - 2-Speed Torque-On-Demand: Notes

Special Tool(s)

Courtesy of FORD MOTOR COMPANY	Handle 205-D055 (D81L-4000-A) or equivalent
Courtesy of FORD MOTOR COMPANY	Holding Fixture, Transmission 307-003 (T57L-500-B)
Courtesy of FORD MOTOR COMPANY	Installer, Front Axle Oil Seal 205-350 (T95T-3010-A)
Courtesy of FORD MOTOR COMPANY	Installer, Input Shaft Bearing 308-085 (T83T-7025-C)
Courtesy of FORD MOTOR COMPANY	Installer, Input Shaft Oil Seal 308-186 (T90T-7127-B)
Courtesy of FORD MOTOR COMPANY	Installer, Input Shaft Oil Seal 308-249 (T96T-7127-A)
Courtesy of FORD MOTOR COMPANY	Installer, Mainshaft Bearing 308-060 (T77J-7025-K)
Courtesy of FORD MOTOR COMPANY	Installer, Output Shaft Front Bearing 308-410
Courtesy of FORD MOTOR COMPANY	Installer, Valve Stem Oil Seal 303-367 (T90P-6510-AH)
Courtesy of FORD MOTOR COMPANY	Remover, Bearing Cup 308-047 (T77F-1102-A)
Courtesy of FORD MOTOR COMPANY	Slide Hammer 100-001 (T50T-100-A)

Material

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

2-Speed Transfer Case - Rear Half

Fig 1: Exploded View Of 2-Speed Transfer Case (Rear Half) With Torque Specifications

Courtesy of FORD MOTOR COMPANY

Item	Part Number	Description
1	7917	Snap ring
2	7N063	Spacer
3	7D221	Caged thrust bearing
4	7G362	Hub and coil housing
5	7A534	Ball (3 required)
6	7R428	Cam
7	7D126	Wave spring
8	7917	Snap ring
9	7C108	Clutch assembly
10	7177	Drive sprocket
11	7D221	Caged thrust bearing
12	7C341	Thrust washer (2 required)
13	7A149	Oil pump assembly
14	7H298	Hose clamp
15	4090	Oil pump pickup hose
16	7A098	Oil pickup and filter
17	7G361	Transfer case field coil
18	7025	Rear output shaft support bearing
19	7025	Front output shaft rear bearing
20	7005	Case
21	-	Output shaft bushing (part of 7005)
22	7A443	Transfer case bolts (20 required)
23	7A010	Fill plug
24	7045	Coil nut (3 required)
25	N800670-S-S	Shift motor bolt (3 required)
26	7A443C	Shift motor bracket bolt
27	7G360	Transfer case shift motor
28	7H298	Inner connector retainer
29	7B215	Shift motor seal
30	7B368	Washer (3 required)
31	7H150	Armature

2-Speed Transfer Case - Front Half

Fig 2: Exploded View Of 2-Speed Transfer Case (Front Half)

Courtesy of FORD MOTOR COMPANY

Item	Part Number	Description
31	7A153	Ring gear
32	7064	Snap ring
33	7A398	Front planet carrier
34	7D221	Front planet needle bearing
35	7D164	Reduction hub
36	7061	Output shaft
37	7389	Shift fork
38	7C430	Shift fork pad (2 required)
39	7240	Shift fork shaft
40	7F063	Shift cam assembly
41	7A029	Drive chain
42	7177	Driven sprocket
43	7917	Snap ring
44	7025	Front output shaft support bearing
45	7E290	Magnet
46	7005	Case
47	7B362	Dowel
48	7025	Front input shaft support bearing
49	7B215	Front output shaft oil seal
50	7061	Front output shaft
51	7034	Vent tube
52	7B215	Front input shaft seal