LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Lincoln >> 2011 >> Navigator RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Transfer Case) >> Disassembly And Assembly >> Transfer Case - Navigator >> Assembly
July 1: So it begins. Don't worry, this is not in the correct legal jurisdiction!

Transfer Case - Navigator: Assembly

WARNING: This page is about a different variant/trim than selected.
  1. Lubricate all internal components with the recommended transfer case lubricant during reassembly.
  2. Clean the mating surfaces of the cases.
  3. Using a suitable press and the Output Shaft Front Bearing Installer with the Handle, install the front input shaft bearing.
    Fig 1: Installing Front Input Shaft Bearing
    G07458801Courtesy of FORD MOTOR CO.
  4. Using a suitable press and the Front Axle Oil Seal Installer with the Handle, install the front shaft support bearing.
    Fig 2: Installing Front Shaft Support Bearing
    G07458802Courtesy of FORD MOTOR CO.
  5. Using the Input Shaft Oil Seal Installer, install a new front output shaft seal.
    Fig 3: Installing Front Output Shaft Seal
    G07458803Courtesy of FORD MOTOR CO.
  6. Install the case to the Transmission Holding Fixture. Secure the case and the Transmission Holding Fixture to the work bench.
    Fig 4: Securing Transfer Case To Work Bench
    G07458804Courtesy of FORD MOTOR CO.
  7. Using the Input Shaft Oil Seal Installer, install a new front input shaft seal.
    Fig 5: Installing Front Input Shaft Seal
    G07458805Courtesy of FORD MOTOR CO.
  8. Install the front output shaft and the snap ring.
    Fig 6: Locating Snap Ring And Front Output Shaft
    G07458806Courtesy of FORD MOTOR CO.
  9. Install the input shaft.
    Fig 7: Locating Input Shaft
    G07458807Courtesy of FORD MOTOR CO.
  10. Install the output shaft.
    Fig 8: Locating Output Shaft
    G07458808Courtesy of FORD MOTOR CO.
  11. NOTE: Make sure the oil pump finger is in the slot in the case.

    Install the oil pump assembly.

    Fig 9: Locating Oil Pump Assembly
    G07458809Courtesy of FORD MOTOR CO.
  12. Install the oil pan magnet into the slot in the case.
  13. Install the 3-piece thrust bearing assembly: the thrust washer, thrust bearing and thrust washer.
  14. Install the drive chain and the sprockets as an assembly.
    Fig 10: Locating Drive Chain And Sprockets Assembly
    G07458810Courtesy of FORD MOTOR CO.
  15. NOTE: When installing the clutch assembly, do not separate the clutch pack assembly. The thrust washer in the lower clutch pack uses tabs to hold it in place. If the thrust washer is not in place, a transfer case clearance problem will occur.
    NOTE: If the clutch pack is disassembled, a new clutch pack must be installed and the armature transferred. Failure to install a new clutch pack can result in component failure.

    Install the clutch pack assembly with the armature. Make sure to align the clutch pack with the sprocket.

    Fig 11: Locating Clutch Pack Assembly
    G07458811Courtesy of FORD MOTOR CO.
  16. Install a new snap ring.
    Fig 12: Locating Snap Ring
    G07458812Courtesy of FORD MOTOR CO.
  17. Install the wave spring.
    Fig 13: Locating Wave Spring
    G07458813Courtesy of FORD MOTOR CO.
  18. Install the cam and the steel balls.
    Fig 14: Locating Steel Balls And Cam
    G07458814Courtesy of FORD MOTOR CO.
  19. Install the cam/coil housing.
    Fig 15: Locating Cam/Coil Housing
    G07458815Courtesy of FORD MOTOR CO.
  20. Install the caged thrust bearing assembly.
    Fig 16: Locating Caged Thrust Bearing Assembly
    G07458816Courtesy of FORD MOTOR CO.
  21. Install the spacer.
    Fig 17: Locating Spacer
    G07458817Courtesy of FORD MOTOR CO.
  22. Install the snap ring.
    Fig 18: Locating Snap Ring
    G07458818Courtesy of FORD MOTOR CO.
  23. Using a suitable press and the Mainshaft Bearing Installer, install the rear output shaft support bearing.
    Fig 19: Installing Rear Output Shaft Support Bearing
    G07458819Courtesy of FORD MOTOR CO.
  24. Using a suitable press and the Mainshaft Bearing Installer, install the front output shaft rear bearing.
    Fig 20: Installing Front Output Shaft Rear Bearing
    G07458820Courtesy of FORD MOTOR CO.
  25. NOTE: Applying too much silicone sealant will plug the fluid filter and cause transfer case failure.

    Apply a bead of silicone sealant to the transfer case mating surface. Position the 2 transfer case halves together, aligning the coil studs through the case holes. Tighten the 20 transfer case bolts evenly in a star pattern.

    • Tighten to 29 Nm (21 lb-ft).
    Fig 21: Locating Transfer Case Bolts
    G07458821Courtesy of FORD MOTOR CO.
  26. Install the 3 coil washers and nuts.
    • Tighten to 10 Nm (89 lb-in).
  27. Using the Input Shaft Oil Seal Installer, install the rear output shaft seal.
    Fig 22: Installing Rear Output Shaft Seal
    G07458822Courtesy of FORD MOTOR CO.
  28. NOTE: After the wire is inserted into the connector, gently pull the wire back to verify the pin is locked inside the connector.

    Insert the coil wire pin in the electrical connector and install the inner connector retainer.

    Fig 23: Locating Coil Wire Pin (Blue Wire)
    G07458823Courtesy of FORD MOTOR CO.
  29. Install the connector bracket and the 2 connector bracket bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 24: Locating Connector Bracket Bolts
    G07458824Courtesy of FORD MOTOR CO.
  30. Secure the transfer case to a suitable transmission jack and remove the transfer case from the Transmission Holding Fixture.
Fig 25: Removing Transfer Case From Transmission Holding Fixture
G07458825Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals