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

WARNING: This page is about a different car, the 2018 Ford F-550 Super Duty, 2018 Ford F-450 Super Duty, 2018 Ford F-350 Super Duty, and 2018 Ford F-250 Super Duty. 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.

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.

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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.

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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.

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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.

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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.

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Using the special tools, install the input shaft seal. Use Special Service Tool: 205-1018 Installation Tube., 308-943 Installer, Input Seal.

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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.

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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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Install the manual shift assembly.
- Install the shift guide plate and guide plate spring arm.
- Install the shift lever.
- Tighten the shift lever set screw.
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Install the ring gear and the ring gear circlip.

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Install the planet carrier and the front planet carrier thrust bearing.

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Install the shift fork assembly.

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NOTE: The pump assembly is not repairable.

Install the magnet and oil pump assembly.

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Install the output shaft.

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Install the center bearing support assembly.

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Install the shift rail.

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Install the drive chain and the sprockets as an assembly.

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Install the lock hub shift fork assembly.

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Install the shift fork lock hub and align shift fork slide grooves.

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Install the shift lock hub snap ring.

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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: Motorcraft ® Ultra Silicone Sealant / TA-29

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Position the transfer case halves and tighten the bolts in the sequence shown.
Torque: 23 lb.ft (31 Nm)

Fig 1: Transfer Case Tightening Sequence (Manual Shift Transfer Case)
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Install the transfer case rear seal. Refer to: Transfer Case Rear Seal .
Remove the transfer case from the transmission adjustable mounting arms. Use the General Equipment: Adjustable Mounting Arm

GFD205317

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