Transfer Case: Assembly

WARNING: This page is about a different variant/trim than selected.

Lubricate all internal components with the recommended transfer case lubricant during reassembly.
Clean the mating surfaces of the cases.
Using a suitable press and the special tools, install the front planet support bearing.

Fig 1: Installing Front Planet Support Bearing
Courtesy of FORD MOTOR CO.
Using a suitable press and the special tools, install the front output shaft support bearing.

Fig 2: Installing Front Output Shaft Support Bearing
Courtesy of FORD MOTOR CO.
Using the special tool, install a new oil seal.

Fig 3: Installing A New Oil Seal
Courtesy of FORD MOTOR CO.

CAUTION: Be careful not to crush the seal.

Fig 4: Installing New Shifter Shaft Seal

G03934112

Courtesy of FORD MOTOR CO.

Using the special tool, install a new shifter shaft seal.
Install the case to the transmission holding fixture. Secure the case to the work bench.
Using the special tools, install a new oil seal.

Fig 5: Installing New Oil Seal
Courtesy of FORD MOTOR CO.
Install the ring gear.
1. Position the ring gear in the case.
2. Install the snap ring.
  
  Fig 6: Installing Ring Gear
  Courtesy of FORD MOTOR CO.
Install the front output shaft and the snap ring.

Fig 7: Installing Front Output Shaft And Snap Ring
Courtesy of FORD MOTOR CO.

NOTE: If removed, using a suitable press and the special tool 308-085, install the needle bearing into the front planet. Be careful not to crush the bearing cage.

Fig 8: Installing Front Planet

G03934101

Courtesy of FORD MOTOR CO.

Install the front planet.
Install the shift fork shaft.

Fig 9: Installing Shift Fork Shaft
Courtesy of FORD MOTOR CO.

NOTE: Assemble the reduction hub and the reduction shift fork.

Fig 10: Installing Reduction Shift Fork, Reduction Hub, And Shift Cam As An Assembly

G03934099

Courtesy of FORD MOTOR CO.

Install the reduction shift fork, the reduction hub, and the shift cam as an assembly.
Install the output shaft.

Fig 11: Installing Output Shaft
Courtesy of FORD MOTOR CO.
Install the oil pump assembly.
- Make sure the oil pump finger is in the slot in the case.
  
  Fig 12: Installing Oil Pump Assembly
  Courtesy of FORD MOTOR CO.
Install the oil pan magnet into its slot in the case.

Fig 13: Installing Oil Pan Magnet Into Its Slot In Case
Courtesy of FORD MOTOR CO.
Install the output shaft hub.

Fig 14: Installing Output Shaft Hub
Courtesy of FORD MOTOR CO.

NOTE: Assemble the lockup collar and the lockup fork.

Fig 15: Installing Lockup Collar And Lockup Fork As An Assembly

G03934094

Courtesy of FORD MOTOR CO.

Install the lockup collar and the lockup fork as an assembly.
Install the three-piece thrust bearing assembly.
1. Install the thrust washer.
2. Install the thrust bearing.
3. Install the thrust washer.
  
  Fig 16: Installing Three-Piece Thrust Bearing Assembly
  Courtesy of FORD MOTOR CO.
Install the drive chain and the sprockets as an assembly.

Fig 17: Installing Drive Chain And Sprockets As An Assembly
Courtesy of FORD MOTOR CO.

CAUTION: 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 can occur.

Fig 18: Installing Clutch Pack Assembly

G03934126

Courtesy of FORD MOTOR CO.

Install the clutch pack assembly.
Install the lockup shift fork spring.

Fig 19: Installing Lockup Shift Fork Spring
Courtesy of FORD MOTOR CO.
Install a new snap ring.

Fig 20: Installing New Snap Ring
Courtesy of FORD MOTOR CO.
Install the wave spring.

Fig 21: Installing Wave Spring
Courtesy of FORD MOTOR CO.
Install the cam and the steel balls.

Fig 22: Installing Cam And Steel Balls
Courtesy of FORD MOTOR CO.
Install the cam/coil housing.

Fig 23: Installing Cam/Coil Housing
Courtesy of FORD MOTOR CO.
Install the thrust bearing assembly.

Fig 24: Installing Thrust Bearing Assembly
Courtesy of FORD MOTOR CO.
Install the snap ring.

Fig 25: Installing Snap Ring
Courtesy of FORD MOTOR CO.
Using a suitable press and the special tool, install the rear output shaft support bearing.

Fig 26: Installing Rear Output Shaft Support Bearing
Courtesy of FORD MOTOR CO.
Using a suitable press and the special tool, install the front output shaft rear bearing.

Fig 27: Installing Front Output Shaft Rear Bearing
Courtesy of FORD MOTOR CO.

CAUTION: Applying too much silicone sealant can plug the fluid filter and cause transfer case failure.

Apply a bead of silicone sealant to the transfer case mating surfaces, then position the two transfer case halves together. Tighten the bolts evenly in a star pattern.
- Position the coil studs through the case holes, make sure the shift cam shaft is aligned with its case bore, and the lockup shift fork spring is in position.
  
  Fig 28: Positioning Transfer Case Halves
  Courtesy of FORD MOTOR CO.
  
  Fig 29: Tightening Transfer Case Bolts
  Courtesy of FORD MOTOR CO.
Install the coil washers and nuts.

Fig 30: Installing Coil Washers And Nuts
Courtesy of FORD MOTOR CO.
Using the special tool, install the oil seal.

Fig 31: Installing Oil Seal
Courtesy of FORD MOTOR CO.
Install the transfer case shift motor.

Fig 32: Installing Transfer Case Shift Motor
Courtesy of FORD MOTOR CO.
Install the coil wire pin in the electrical connector.
1. Remove the wire connector spacer.
2. Install the coil wire pin. Reinstall the wire connector spacer.
  
  Fig 33: Installing Coil Wire Pin In Electrical Connector
  Courtesy of FORD MOTOR CO.
Remove the transfer case from the special tool.

Fig 34: Removing Transfer Case From Special Tool
Courtesy of FORD MOTOR CO.