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Transfer Case: Assembly

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Prior to assembly, lubricate all parts with MERCON® Multi-Purpose (ATF) Transmission Fluid.
  1. Using the special tools and a suitable press, install the bearing.
    Fig 1: Installing Bearing
    G03276456Courtesy of FORD MOTOR CO.
  2. Install the snap ring.
    Fig 2: Installing Snap Ring
    G03276457Courtesy of FORD MOTOR CO.
  3. Using the special tool, install the oil seal.
    Fig 3: Installing Oil Seal
    G03276458Courtesy of FORD MOTOR CO.
    4. CAUTION: Do not crush the needle bearing.
    Fig 4: Installing Needle Bearing
    G03276459Courtesy of FORD MOTOR CO.
  4. Using the special tools and a suitable press, install the needle bearing.
  5. Using the special tools and a suitable press, install the sleeve bearing.
    Fig 5: Installing Sleeve Bearing
    G03276460Courtesy of FORD MOTOR CO.
    6. NOTE: The recessed face of the sun gear must face the rear of the transfer case.
    Fig 6: Installing Sun Gear, Thrust Plate, And Snap Ring
    G03276461Courtesy of FORD MOTOR CO.
  6. Install the sun gear, the thrust plate, and the snap ring.
    7. NOTE: The stepped face of the thrust washer must face upward.
    Fig 7: Installing Input Shaft Assembly And Thrust Washer
    G03276462Courtesy of FORD MOTOR CO.
  7. Install the input shaft assembly and the thrust washer.
    8. NOTE: Install the bearing on the input shaft assembly so that the snap ring groove in the bearing is closest to the top of the planet carrier.
    Fig 8: Installing Bearing
    G03276463Courtesy of FORD MOTOR CO.
  8. Using a suitable press, install the bearing.
  9. Install the snap ring.
    Fig 9: Installing Snap Ring
    G03276464Courtesy of FORD MOTOR CO.
  10. Using the special tool, install the oil seal.
    Fig 10: Installing Oil Seal
    G03276465Courtesy of FORD MOTOR CO.
  11. Install the large snap ring in the groove in the front adapter.
    Fig 11: Installing Large Snap Ring In Front Adaptor
    G03276466Courtesy of FORD MOTOR CO.
    12. CAUTION: Install the front adapter within 15 minutes of applying the silicone sealant or it will be necessary to apply new sealant. If possible, allow one hour before filling the transfer case with lubricant to allow the silicone sealant to cure.
    Fig 12: Applying Bead Of Silicone Sealant To Front Adapter Mounting Surface
    G03276467Courtesy of FORD MOTOR CO.
  12. Apply a 3-mm (1/8-inch) bead of silicone sealant to the front adapter mounting surface of the transfer case.
  13. Position the front adapter on the transfer case, and install the six bolts.
    Fig 13: Positioning Front Adapter On Transfer Case
    G03276468Courtesy of FORD MOTOR CO.
  14. Install the input shaft assembly and the complete carrier assembly as an assembly.
    • Align the pinion gears gear teeth and the ring gear teeth. Expand the snap ring and push inward on the planet carrier until the input shaft assembly seats fully in the front adapter. Verify that the snap ring engaged the assembly by holding the front adapter and lightly tapping the face of the input shaft assembly against a wooden block.
      Fig 14: Installing Input Shaft Assembly And Complete Carrier Assembly
      G03276469Courtesy of FORD MOTOR CO.
  15. Attach the front case to the special tool.
    Fig 15: Attaching Front Case To Special Tool
    G03276470Courtesy of FORD MOTOR CO.
  16. Install the new shift fork facings. Verify that they snap securely into place.
    Fig 16: Installing Shift Fork Facings
    G03276471Courtesy of FORD MOTOR CO.
  17. Install the reduction hub and the reduction fork assembly as an assembly.
    Fig 17: Installing Reduction Hub And Reduction Fork Assembly
    G03276472Courtesy of FORD MOTOR CO.
    18. CAUTION: The oil pump spring pin must be installed at the correct height to make sure that the oil pump shaft rotates with the rear output shaft.
    NOTE: If a measurement was not taken during disassembly, install the pin to the correct height specification using a micrometer.
    Fig 18: Pressing Pin Into Rear Output Shaft Pin Hole
    G03276473Courtesy of FORD MOTOR CO.
  18. Press the pin into the rear output shaft pin hole to the previously measured height.
    19. NOTE: Do not remove the plastic insert from the bore of a new pump assembly. Discard it after it slides out of the bore during the pump assembly installation on the rear output shaft.
  19. Install the pump assembly on the rear output shaft.
    • Align the keyway in the cover and the spring pin in the rear output shaft and fully seat the pump assembly on the shaft. The shaft will rotate freely in the pump assembly when the pump assembly is fully seated.
      Fig 19: Installing Pump Assembly On Rear Output Shaft
      G03276474Courtesy of FORD MOTOR CO.
  20. If the pump assembly does not turn freely, realign the keyway and the spring pin and jiggle the pump assembly until it seats fully and rotates freely on the shaft.
    Fig 20: Aligning Keyway And Spring Pin
    G03276475Courtesy of FORD MOTOR CO.
  21. Prime the pump assembly.
    • Submerge the pump in a container full of clean MERCON® Multi-Purpose (ATF) Transmission Fluid.
  22. Install the rear output shaft and the pump assembly.
    Fig 21: Installing Rear Output Shaft And Pump Assembly
    G03276476Courtesy of FORD MOTOR CO.
  23. Install the oil strainer and the magnet in the slot in the case.
    Fig 22: Installing Oil Strainer And Magnet In Slot In Case
    G03276477Courtesy of FORD MOTOR CO.
  24. Install the front output shaft assembly.
    Fig 23: Installing Front Output Shaft Assembly
    G03276478Courtesy of FORD MOTOR CO.
  25. Install the snap ring.
    Fig 24: Installing Snap Ring
    G03276479Courtesy of FORD MOTOR CO.
  26. Install the drive chain, the drive sprocket and the driven sprocket as an assembly.
    Fig 25: Installing Drive Chain, Drive Sprocket And Driven Sprocket
    G03276480Courtesy of FORD MOTOR CO.
  27. Install the spacer and the snap ring.
    Fig 26: Installing Spacer And Snap Ring
    G03276481Courtesy of FORD MOTOR CO.
  28. Install the shift rail through the reduction shift fork. Verify that the shift rail seats in the case bore.
    Fig 27: Installing Shift Rail Through Reduction Shift Fork
    G03276482Courtesy of FORD MOTOR CO.
  29. Slide the spacer and the torsion spring on the shift shaft and position it beneath the drive tang.
    Fig 28: Sliding Spacer And Torsion Spring On Shift Shaft
    G03276483Courtesy of FORD MOTOR CO.
    30. WARNING: Keep fingers away from spring ends. Failure to follow these instructions can result in personal injury.
    Fig 29: Positioning First Spring Tang To Left Of Drive Tang
    G03276484Courtesy of FORD MOTOR CO.
  30. Position the first spring tang to the left of the drive tang.
    31. WARNING: Keep fingers away from spring ends. Failure to follow these instructions can result in personal injury.
    Fig 30: Winding Second Spring Tang Clockwise
    G03276485Courtesy of FORD MOTOR CO.
  31. Wind the second spring tang clockwise past the drive tang, and push the torsion spring and sleeve in as far as it will go.
  32. Install the electric shift cam, and slide the drive tang between the torsion spring tangs as far as it will go.
    Fig 31: Installing Electric Shift Cam
    G03276486Courtesy of FORD MOTOR CO.
    33. CAUTION: Do not bend the cam during installation. This will damage the pin on the end of the shift shaft.
    Fig 32: Installing Pin On End Of Shift Shaft Into Hole In Case
    G03276487Courtesy of FORD MOTOR CO.
  33. Install the pin on the end of the shift shaft into the hole in the case.
  34. Position the torsion spring tangs so that they point toward the top side of the case and just touch the reduction shift fork.
    Fig 33: Positioning Torsion Spring Tangs
    G03276488Courtesy of FORD MOTOR CO.
  35. Assemble the lockup assembly.
    Fig 34: Assembling Lockup Assembly
    G03276489Courtesy of FORD MOTOR CO.
  36. Press downward on the lockup hub and install the snap ring.
    Fig 35: Installing Snap Ring
    G03276490Courtesy of FORD MOTOR CO.
  37. Install the lockup fork and the lockup collar as an assembly.
    Fig 36: Installing Lockup Fork And Lockup Collar
    G03276491Courtesy of FORD MOTOR CO.
    38. NOTE: After the lockup fork is released, verify that the cam roller is resting on the top surface of the electric shift cam and not into an inside track.
    Fig 37: Identifying Triangular Shaft
    G03276492Courtesy of FORD MOTOR CO.
  38. The triangular shaft will be in the two-wheel high (2H) position at final assembly.
  39. Lift upward on the lockup fork slightly while holding down on the shift rail and rotate the electric shift cam track into the cam roller by turning the shift shaft.
    Fig 38: Rotating Electric Shift Cam Track Into Cam Roller
    G03276493Courtesy of FORD MOTOR CO.
  40. Install the shift collar hub and the return spring.
    Fig 39: Installing Shift Collar Hub And Return Spring
    G03276494Courtesy of FORD MOTOR CO.
    41. CAUTION: Do not crush the needle bearing.
    Fig 40: Installing Needle Bearing
    G03276495Courtesy of FORD MOTOR CO.
  41. Using the special tools and a suitable press, install the needle bearing.
  42. Using the special tools and a suitable press, install the bearing.
    Fig 41: Installing Bearing
    G03276496Courtesy of FORD MOTOR CO.
  43. Install the snap ring that retains the bearing to the transfer case cover.
    Fig 42: Installing Snap Ring
    G03276497Courtesy of FORD MOTOR CO.
  44. Using the special tool, install the oil seal.
    Fig 43: Installing Oil Seal
    G03276498Courtesy of FORD MOTOR CO.
    45. CAUTION: Assemble the cases within 15 minutes of applying the silicone sealant or it will be necessary to apply new sealant. If possible, allow one hour before filling the transfer case with lubricant to allow the silicone sealant to cure.
  45. Apply a 3-mm (1/8-in) bead of silicone sealant to the mating surface of the front case.
  46. Assemble the cases.
    • Align the output shaft, the shift shaft, and the return spring to their respective bores in the transfer case cover.
      Fig 44: Assembling Cases
      G03276499Courtesy of FORD MOTOR CO.
  47. Install the bolts.
    Fig 45: Installing Case Cover Bolts
    G03276500Courtesy of FORD MOTOR CO.
  48. Install the bolts.
    Fig 46: Installing Case Cover Bolts
    G03276501Courtesy of FORD MOTOR CO.
  49. Install the spacer on the rear output shaft.
    Fig 47: Installing Spacer On Rear Output Shaft
    G03276502Courtesy of FORD MOTOR CO.
  50. Using the special tool, install the oil seal.
    Fig 48: Installing Oil Seal
    G03276503Courtesy of FORD MOTOR CO.
    51. CAUTION: Align the index marks.
    NOTE: Be sure the oil seal is not on the shaft before installing the shaft.
    Fig 49: Holding Flange With Special Tool
    G03276504Courtesy of FORD MOTOR CO.
  51. Position the flange on the rear output shaft. If necessary, reseat the oil seal in the flange.
  52. Install a new oil seal in the flange.
  53. Using the special tool, install the flange. Tighten the nut on the special tool to 54 N.m (40 lb-ft) to seat the flange on the shaft.
    Fig 50: Installing Oil Seal In Flange
    G03276505Courtesy of FORD MOTOR CO.
  54. Use the special tool to prevent the flange from turning. Install a new washer and a new nut.
    Fig 51: Installing Washer And Nut
    G03276506Courtesy of FORD MOTOR CO.
  55. If the shift shaft will not stay in the 4H position, rotate the shift shaft clockwise to the 2H position. During motor assembly and connector installation, rotate the motor assembly counterclockwise until the motor assembly aligns with the mounting holes.
    Fig 52: Rotating Shift Shaft Clockwise To Align Motor Assembly With Mounting Holes
    G03276507Courtesy of FORD MOTOR CO.
    56. CAUTION: Install the motor assembly within 15 minutes of applying the silicone sealant or it will be necessary to apply new sealant. If possible, allow one hour before filling the transfer case with lubricant to allow the silicone sealant to cure.
  56. Apply a thin coat of silicone sealant to the base of the motor housing.
  57. Install the motor assembly and connector.
    Fig 53: Installing Motor Assembly And Connector (1 Of 2)
    G03276508Courtesy of FORD MOTOR CO.
    Fig 54: Installing Motor Assembly And Connector (2 Of 2)
    G03276509Courtesy of FORD MOTOR CO.
  58. Install the transfer case. For additional information, refer to TRANSFER CASE .
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