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

WARNING: This page is about a different car, the 2021 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. Remove the contamination and deposits from the transfer case housing and cover using a plastic scraper. Clean the transfer case housing and cover using a soft bristle brush to remove the contamination. Clean any remaining lip seal coating that may still be present on the housing or cover bores with a wire brush. Make sure the vent fitting and housing pockets are clean and clear. Use the General Equipment: Spatula
    GFD559928Courtesy of FORD MOTOR COMPANY
  2. Clean the transfer case housing and cover flange sealing surfaces. Refer to: RTV Sealing Surface Cleaning and Preparation .
    GFD559929Courtesy of FORD MOTOR COMPANY
  3. Using the special tools, install the shift shaft seal.

    Use Special Service Tool: 307-549 Installer, Shift Shaft Fluid Seal.

    GFD559930Courtesy of FORD MOTOR COMPANY
  4. 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.

    GFD559931Courtesy of FORD MOTOR COMPANY
  5. 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.

    GFD559932Courtesy of FORD MOTOR COMPANY
  6. 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.

    GFD559933Courtesy of FORD MOTOR COMPANY
  7. 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.

    GFD559934Courtesy of FORD MOTOR COMPANY
  8. Using the special tool, install the front output shaft seal.

    Use Special Service Tool: 308-250 (T96T-7127-B) Installer, Output Shaft Oil Seal.

    GFD559935Courtesy of FORD MOTOR COMPANY
  9. Using the special tool, install the input shaft seal.

    Use Special Service Tool: 308-250 (T96T-7127-B) Installer, Output Shaft Oil Seal.

    GFD559936Courtesy of FORD MOTOR COMPANY
  10. Install the front output shaft.
    GFD559920Courtesy of FORD MOTOR COMPANY
  11. Install the front output shaft dust cover.
    GFD559919Courtesy of FORD MOTOR COMPANY
  12. Install the ring gear.
    GFD559918Courtesy of FORD MOTOR COMPANY
  13. 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.

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

    Install the front planet carrier.

    GFD559917Courtesy of FORD MOTOR COMPANY
  15. Install the ring gear circlip.
    GFD559916Courtesy of FORD MOTOR COMPANY
  16. Install the planet carrier thrust bearing.
    GFD559915Courtesy of FORD MOTOR COMPANY
  17. Install the electric shift cam assembly.
    GFD559914Courtesy of FORD MOTOR COMPANY
  18. Install the reduction hub.
    GFD559913Courtesy of FORD MOTOR COMPANY
  19. Install the output shaft.
    GFD559912Courtesy of FORD MOTOR COMPANY
  20. Install the shift fork.
    GFD559911Courtesy of FORD MOTOR COMPANY
  21. Install the shift rail.
    GFD559910Courtesy of FORD MOTOR COMPANY
  22. Install the oil pump assembly.
    GFD559909Courtesy of FORD MOTOR COMPANY
  23. Install the magnet into its slot in the case.
    GFD559908Courtesy of FORD MOTOR COMPANY
  24. Install the sprocket thrust washer.
    GFD559907Courtesy of FORD MOTOR COMPANY
  25. NOTE: Install the drive chain and sprockets as an assembly.

    Install the drive chain and sprockets.

    GFD559906Courtesy of FORD MOTOR COMPANY
  26. Install the lock up hub, shift fork and shift fork spring.
    GFD559904Courtesy of FORD MOTOR COMPANY
  27. Install the field coil housing.
    GFD559903Courtesy of FORD MOTOR COMPANY
  28. Install the field coil housing snap ring.
    GFD559902Courtesy of FORD MOTOR COMPANY
  29. Install the transfer case field coil.
    GFD559901Courtesy of FORD MOTOR COMPANY
  30. If dowel pin is damaged install new dowel pin.
    GFD559900Courtesy of FORD MOTOR COMPANY
  31. 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 (WSS-M4G323-A8)

    GFD559937Courtesy of FORD MOTOR COMPANY
  32. 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)

    Fig 1: Tightening Transfer Case Halves Bolts In Sequence
    GFD559938Courtesy of FORD MOTOR COMPANY
  33. Install the transfer case field coil washers and the nuts.

    Torque

    : 89 lb.in (10 Nm)

    GFD559897Courtesy of FORD MOTOR COMPANY
  34. Clean the transfer case shift motor mating surface.
    GFD559939Courtesy of FORD MOTOR COMPANY
  35. Apply a small bead of silicone sealant to the transfer case shift motor mating surface.

    Material

    : Motorcraft® Ultra Silicone Sealant / TA-29 (WSS-M4G323-A8)

    GFD559940Courtesy of FORD MOTOR COMPANY
  36. 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)

    GFD559941Courtesy of FORD MOTOR COMPANY
  37. 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.

    GFD559863Courtesy of FORD MOTOR COMPANY
  38. Using the special tool, install the rear output shaft seal.

    Use Special Service Tool: 308-249 (T96T-7127-A) Installer, Input Shaft Oil Seal.

    GFD559942Courtesy of FORD MOTOR COMPANY
  39. Install the vibration damper to the transfer case.

    Torque

    : 177 lb.in (20 Nm)

    GFD559895Courtesy of FORD MOTOR COMPANY
  40. Remove the transfer case from the transmission adjustable mounting arms.

    Use the General Equipment: Adjustable Mounting Arm

GFD559893Courtesy of FORD MOTOR COMPANY
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