LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Ford >> 2021 >> Mustang Mach 1, Standard Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 221 (Transfer Case) >> Disassembly And Assembly >> Transfer Case - Vehicles With: Electronic Shift Transfer Case >> Assembly
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Transfer Case - Vehicles With: Electronic Shift Transfer Case: Assembly

WARNING: This page is about a different car, the 2019 Ford F-550 Super Duty, 2019 Ford F-450 Super Duty, 2019 Ford F-350 Super Duty, and 2019 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.

All vehicles except vehicles equipped with a 6R100 transmission built on or after 31-03-2017 

  1. Using the special tools, install the center support bearing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-344 (T95P-7H150-A) Installer, Driven Sprocket Wheel.
    GFD409506Courtesy of FORD MOTOR COMPANY

    All vehicles 

  2. Using the special tools, install the front planet carrier bearing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 308-410 Installer, Output Shaft Front Bearing.
    GFD409507Courtesy of FORD MOTOR COMPANY
  3. Using the special tools, install the front output shaft bearing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-626 Installer, Differential Seal.
    GFD409508Courtesy of FORD MOTOR COMPANY
  4. Using the special tools, install the front output shaft support bearing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-626 Installer, Differential Seal.
    GFD409509Courtesy of FORD MOTOR COMPANY
  5. Using the special tools, install the rear output shaft bearing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 308-410 Installer, Output Shaft Front Bearing.
    GFD409510Courtesy of FORD MOTOR COMPANY
  6. Using the special tools, install the shift shaft seal. Install Special Service Tool: 307-549 Installer, Shift Shaft Fluid Seal.
    GFD409511Courtesy of FORD MOTOR COMPANY
  7. Using the special tools, install the input shaft seal. Use Special Service Tool: 205-1018 Installation Tube., 308-943 Installer, Input Seal.
    GFD409512Courtesy of FORD MOTOR COMPANY
  8. Using the special tools, install the front output shaft seal. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 308-944 Installer, Front Output Seal.
    GFD409513Courtesy of FORD MOTOR COMPANY
  9. 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.

    GFD409498Courtesy of FORD MOTOR COMPANY
  10. Install the ring gear and the ring gear circlip.
    GFD409497Courtesy of FORD MOTOR COMPANY
  11. Install the planet carrier and the front planet carrier thrust bearing.
    GFD409496Courtesy of FORD MOTOR COMPANY
  12. Install the electric shift cam assembly.
    GFD409495Courtesy of FORD MOTOR COMPANY
  13. Install the reduction hub.
    GFD409494Courtesy of FORD MOTOR COMPANY
  14. Install the output shaft.
    GFD409493Courtesy of FORD MOTOR COMPANY
  15. Install the shift fork.
    GFD409492Courtesy of FORD MOTOR COMPANY
  16. Install the shift rail.
    GFD409491Courtesy of FORD MOTOR COMPANY
  17. Install the magnet and oil pump assembly.
    GFD409490Courtesy of FORD MOTOR COMPANY

    All vehicles except vehicles equipped with a 6R100 transmission built on or after 31-03-2017 

  18. Install the center bearing support assembly.
    GFD409514Courtesy of FORD MOTOR COMPANY

    Vehicles equipped with a 6R100 transmission built on or after 31-03-2017 

  19. Install the center support assembly.
    GFD409488Courtesy of FORD MOTOR COMPANY

    All vehicles 

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

    Install the drive chain and sprockets.

    GFD409487Courtesy of FORD MOTOR COMPANY
  21. Assemble the lockup hub assembly.
    GFD409486Courtesy of FORD MOTOR COMPANY
  22. Install the lock up hub assembly, shift fork and shift fork spring.
    GFD409485Courtesy of FORD MOTOR COMPANY
  23. Install the field coil housing.
    GFD409484Courtesy of FORD MOTOR COMPANY
  24. Install the field coil housing snap ring.
    GFD409483Courtesy of FORD MOTOR COMPANY
  25. Install the transfer case field coil.
    GFD409482Courtesy of FORD MOTOR COMPANY
  26. NOTE: Only apply enough silicone sealant to seal the transfer case halves together and does not squeeze into the transfer case.

    Apply a small bead of silicone sealant to the mating surface of the case half.

    Material: Motorcraft® Ultra Silicone Sealant / TA-29

    GFD409515Courtesy of FORD MOTOR COMPANY
  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.

    Torque: 23 lb.ft (31 Nm)

    Fig 1: Transfer Case Component Location W/ Bolt Tightening Sequence
    GFD409516Courtesy of FORD MOTOR COMPANY
  28. Install the transfer case field coil nuts.

    Torque: 89 lb.in (10 Nm)

    GFD409479Courtesy of FORD MOTOR COMPANY
  29. Install the transfer case rear seal. Refer to: Transfer Case Rear Seal - Vehicles With: Flanged Yoke .
  30. Apply a small bead of silicone sealant to the transfer case shift motor mating surface.

    Material: Motorcraft® Ultra Silicone Sealant / TA-29

    GFD409433Courtesy 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)

    GFD409517Courtesy of FORD MOTOR COMPANY
  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.

    GFD409435Courtesy of FORD MOTOR COMPANY
  33. Remove the transfer case from the transmission adjustable mounting arms. Use the General Equipment: Adjustable Mounting Arm
GFD409477Courtesy of FORD MOTOR COMPANY
scientia non olet · About LEMON Manuals