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Home › Ford › 2000 › Contour SVT › Repair and Diagnosis › External Pages › Different car › Section 1181 (Transfer Case - Electronic Shift) › Disassembly And Assembly › Transfer Case › Assembly

Transfer Case: Assembly

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.

    2-Speed TOD vehicles 

    CAUTION: Do not crush the seal.
    Fig 1: Installing Shifter Shaft Seal
    G03949541Courtesy of FORD MOTOR CO.
  1. Using the special tools, install the shifter shaft seal.

    2. All vehicles 

  2. Using the special tools, press the front output shaft support bearing into the case.
    Fig 2: Pressing Front Output Shaft Support Bearing
    G03949542Courtesy of FORD MOTOR CO.
  3. Using the special tool, install the oil seal.
    Fig 3: Installing Oil Seal
    G03949543Courtesy of FORD MOTOR CO.
  4. Using the special tool, install the oil seal.
    Fig 4: Installing Oil Seal
    G03949544Courtesy of FORD MOTOR CO.
  5. Install the front output shaft and flange and snap ring.
    Fig 5: Installing Front Output Shaft And Flange And Snap Ring
    G03949536Courtesy of FORD MOTOR CO.
    6. CAUTION: Do not crush the bearing cage.
    Fig 6: Installing Bushing And Bearing
    G03949546Courtesy of FORD MOTOR CO.
  6. Using a suitable press and the special tool, install the bushing and the bearing, if removed.
  7. Using a suitable press, install the planetary gear carrier support bearing, if removed.
    Fig 7: Installing Planetary Gear Carrier Support Bearing
    G03915504Courtesy of FORD MOTOR CO.
  8. Install the snap ring.
    Fig 8: Installing Snap Ring
    G03949534Courtesy of FORD MOTOR CO.
  9. Install the front planetary gear set assembly.
    1. Expand the snap ring.
    2. Position the front planetary gear set assembly and release the snap ring.
      Fig 9: Positioning Front Planetary Gear Set Assembly
      G03949532Courtesy of FORD MOTOR CO.

    10. 2-Speed TOD vehicles 

  10. Install the shift rail.
    Fig 10: Installing Shift Rail
    G03949530Courtesy of FORD MOTOR CO.
  11. Install the reduction shift fork and the high-low collar as an assembly.
    Fig 11: Installing Reduction Shift Fork And High-Low Collar
    G03949529Courtesy of FORD MOTOR CO.
    12. CAUTION: Do not disassemble the electric shift cam assembly.
    Fig 12: Installing Electric Shift Cam Assembly
    G03949528Courtesy of FORD MOTOR CO.
  12. Install the electric shift cam assembly.

    13. All vehicles 

    CAUTION: Do not disassemble the pump assembly.
    Fig 13: Installing Pump Assembly And Rear Output Shaft
    G03949527Courtesy of FORD MOTOR CO.
  13. Install the pump assembly and the rear output shaft as an assembly.
  14. Install the thrust washer.
    Fig 14: Installing Thrust Washer
    G03949526Courtesy of FORD MOTOR CO.
  15. Install the oil pan magnet.
    Fig 15: Installing Oil Pan Magnet
    G03949525Courtesy of FORD MOTOR CO.
  16. Install the drive chain and the 2 sprockets as an assembly.
    Fig 16: Installing Drive Chain And Sprockets
    G03949524Courtesy of FORD MOTOR CO.
    17. CAUTION: When removing or installing the clutch pack assembly, do not separate the clutch pack assembly. Keep tension on the clutch pack upon removal. Set the clutch pack assembly on the bench in the same position as it was located in the transfer case. 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 can occur.
    Fig 17: Installing Clutch Pack Assembly
    G03949523Courtesy of FORD MOTOR CO.
  17. Install the clutch pack assembly.
    18. CAUTION: Use a new snap ring.
    Fig 18: Installing Snap Ring
    G03949522Courtesy of FORD MOTOR CO.
  18. Install the snap ring.
  19. Install the wave spring.
    Fig 19: Installing Wave Spring
    G03949521Courtesy of FORD MOTOR CO.
  20. Install the apply cam and 3 steel balls.
  21. Install the cam and coil housing assembly.
    Fig 20: Installing Cam And Coil Housing Assembly
    G03949520Courtesy of FORD MOTOR CO.
  22. Install the thrust bearing.
    Fig 21: Installing Thrust Bearing
    G03949519Courtesy of FORD MOTOR CO.
  23. Using the special tools and a suitable press, install the front output shaft rear bearing into the case.
    Fig 22: Installing Front Output Shaft Rear Bearing Into Case
    G03949562Courtesy of FORD MOTOR CO.
  24. Using the special tools and a suitable press, install the rear output shaft rear bearing into the case.
    Fig 23: Installing Rear Output Shaft Rear Bearing Into Case
    G03949562Courtesy of FORD MOTOR CO.
  25. Position and support the clutch coil assembly, then install the 3 nuts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 24: Positioning And Support Clutch Coil Assembly
      G03949515Courtesy of FORD MOTOR CO.
    26. CAUTION: Applying excess silicone rubber can damage the internal components.
    Fig 25: Applying Bead Of Silicone Rubber On Rear Case Mating Surface
    G03949565Courtesy of FORD MOTOR CO.
  26. Apply a 3-mm (0.11-in) bead of silicone rubber on the rear case mating surface.
  27. Assemble the front and rear case halves.
    Fig 26: Assembling Front And Rear Case Halves
    G03949566Courtesy of FORD MOTOR CO.
  28. Install the transfer case bolts.
    • Tighten to 25 Nm (18 lb-ft), evenly in a star pattern.
      Fig 27: Installing Transfer Case Bolts
      G03949514Courtesy of FORD MOTOR CO.
  29. Install the yoke-to-flange oil seal.
    Fig 28: Installing Yoke-To-Flange Oil Seal
    G03949502Courtesy of FORD MOTOR CO.
  30. Install a new output flange oil seal.
    31. NOTE: Align the index marks made during disassembly.
  31. Install the output flange.
  32. Install the output shaft yoke washer.
  33. Using the special tool to hold the output flange and install the nut.
    • Tighten to 355 Nm (262 lb-ft).
      Fig 29: Installing Nut Using Special Tool
      G03949500Courtesy of FORD MOTOR CO.

    34. 2-Speed TOD vehicles 

    NOTE: Make sure the motor mounting surfaces are clean.
    Fig 30: Applying Bead Of Sealant To Motor Mounting Surface On Case
    G03949570Courtesy of FORD MOTOR CO.
  34. Apply a 3-mm (0.11-in) bead of sealant to the motor mounting surface on the case.
  35. Position the transfer case shift motor and install the 4 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 31: Positioning Transfer Case Shift Motor
      G03949571Courtesy of FORD MOTOR CO.
  36. Install the coil wire pin from the electrical connector.
    1. Install the coil wire pin.
    2. Install the connector interlock.
      Fig 32: Installing Connector Interlock
      G03949572Courtesy of FORD MOTOR CO.

    37. All vehicles 

  37. Position the heat shield and install the 2 heat shield bolts, if equipped.
    • Tighten to 15 Nm (11 lb-ft).
      Fig 33: Positioning Heat Shield
      G03949507Courtesy of FORD MOTOR CO.
  38. Install the transfer case in the vehicle. For additional information, refer to TRANSFER CASE .
  39. Fill the transfer case. For additional information, refer to TRANSFER CASE DRAINING AND FILLING .
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