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Home › Lincoln › 2002 › Navigator RWD › Repair and Diagnosis › External Pages › Different variant/trim › Section 5 (Transfer Case - Automatic Shift) › Disassembly And Assembly › Transfer Case › Assembly

Transfer Case: Assembly

WARNING: This page is about a different variant/trim than selected.
  1. Using a suitable press and the special tools, install the front output shaft support bearing, if removed.
    Fig 1: Installing Front Output Shaft Support Bearing
    G03444777Courtesy of FORD MOTOR CO.
  2. Using the special tool, install the oil seal.
    Fig 2: Installing Oil Seal
    G03444778Courtesy of FORD MOTOR CO.
  3. Install the dust shield, if removed.
    Fig 3: Installing Dust Shield
    G03444779Courtesy of FORD MOTOR CO.
    4. NOTE: Support the front output shaft during installation.
    Fig 4: Installing Front Output Shaft
    G03444780Courtesy of FORD MOTOR CO.
  4. Install the front output shaft.
    1. Position the front output shaft.
    2. Install the snap ring.
  5. Install the snap ring.
    Fig 5: Installing Snap Ring
    G03444781Courtesy of FORD MOTOR CO.
  6. Install the ring gear, if removed.
    1. Position the ring gear.
    2. Install the snap ring.
    Fig 6: Installing Snap Ring
    G03444782Courtesy of FORD MOTOR CO.
    7. CAUTION: Be careful not to crush the bearing cage.
    Fig 7: Installing Needle Bearing Into Front Planet
    G03444783Courtesy of FORD MOTOR CO.
  7. If removed, using a suitable press and the special tool, install the needle bearing into the front planet.
  8. If removed, using a suitable press, install the front planet support bearing.
    Fig 8: Installing Front Planet Support Bearing
    G03444784Courtesy of FORD MOTOR CO.
  9. Install the snap ring.
    Fig 9: Installing Snap Ring
    G03444785Courtesy of FORD MOTOR CO.
    10. NOTE: Rotate the front planet for correct positioning in the transfer case.
    Fig 10: Installing Front Planet
    G03444786Courtesy of FORD MOTOR CO.
  10. Install the front planet.
    1. Depress the snap ring.
    2. Position the front planet.
  11. Using the special tools, install the oil seal.
    Fig 11: Installing Oil Seal
    G03444787Courtesy of FORD MOTOR CO.
    12. CAUTION: Be careful not to crush the seal.
    Fig 12: Installing Shifter Shaft Seal
    G03444788Courtesy of FORD MOTOR CO.
  12. Using the special tool, install the shifter shaft seal, if removed.
  13. Using a suitable press and the special tool, install the rear output shaft support bearing, if removed.
    Fig 13: Installing Rear Output Shaft Support Bearing
    G03444789Courtesy of FORD MOTOR CO.
  14. Using a suitable press and the special tool, install the front output shaft rear bearing, if removed.
    Fig 14: Installing Front Output Shaft Rear Bearing
    G03444790Courtesy of FORD MOTOR CO.
  15. Install the shift cam assembly.
    Fig 15: Installing Shift Cam Assembly
    G03444791Courtesy of FORD MOTOR CO.
  16. Install the shift fork shaft.
    Fig 16: Installing Shift Fork Shaft
    G03444792Courtesy of FORD MOTOR CO.
  17. Install the reduction shift fork assembly and the reduction hub as an assembly.
    Fig 17: Installing Reduction Shift Fork Assembly
    G03444793Courtesy of FORD MOTOR CO.
  18. Install the oil pump assembly and the output shaft as an assembly.
    Fig 18: Installing Oil Pump Assembly
    G03444794Courtesy of FORD MOTOR CO.
  19. Install the oil pan magnet into its slot in the case.
    Fig 19: Installing Oil Pan Magnet Into Its Slot In Case
    G03444795Courtesy of FORD MOTOR CO.
  20. Install the lockup collar and assembly and the lockup fork as an assembly.
    Fig 20: Installing Lockup Collar And Assembly And Lockup Fork
    G03444796Courtesy of FORD MOTOR CO.
  21. Install the three-piece thrust bearing assembly (non-directional).
    1. Install the thrust washer.
    2. Install the thrust bearing.
    3. Install the thrust washer.
    Fig 21: Installing Thrust Washer
    G03444797Courtesy of FORD MOTOR CO.
  22. Install the drive chain assembly and the sprockets as an assembly.
    Fig 22: Installing Drive Chain Assembly And Sprockets
    G03444798Courtesy of FORD MOTOR CO.
  23. Install the front output shaft tone wheel.
    Fig 23: Installing Front Output Shaft Tone Wheel
    G03444799Courtesy of FORD MOTOR CO.
    24. CAUTION: When removing or 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 24: Installing Clutch Pack Assembly
    G03444800Courtesy of FORD MOTOR CO.
  24. Install the clutch pack assembly.
  25. Install the new snap ring.
    Fig 25: Installing New Snap Ring
    G03444801Courtesy of FORD MOTOR CO.
  26. Install the wave spring.
    Fig 26: Installing Wave Spring
    G03444802Courtesy of FORD MOTOR CO.
  27. Install the cam and the steel balls.
    1. Install the cam.
    2. Install the steel balls.
    Fig 27: Installing Cam And Steel Balls
    G03444803Courtesy of FORD MOTOR CO.
  28. Install the cam/coil housing.
    Fig 28: Installing Cam/Coil Housing
    G03444804Courtesy of FORD MOTOR CO.
  29. Install the thrust bearing assembly.
    1. Install the thin thrust bearing race.
    2. Install the thrust bearing.
    3. Install the thick thrust bearing race.
    Fig 29: Installing Thick Thrust Bearing Race
    G03444805Courtesy of FORD MOTOR CO.
  30. Install the snap ring.
    Fig 30: Installing Snap Ring
    G03444806Courtesy of FORD MOTOR CO.
  31. Install the lockup shift fork spring.
    Fig 31: Installing Lockup Shift Fork Spring
    G03444807Courtesy of FORD MOTOR CO.
    32. NOTE: Support the coil during installation.
    Fig 32: Tightening Coil Nuts
    G03444808Courtesy of FORD MOTOR CO.
  32. Install the coil if removed.
    1. Position the coil in the case.
    2. Tighten the coil nuts.
    33. CAUTION: Applying too much silicone sealant can plug the fluid filter and cause transfer case failure.
  33. Apply a small bead of silicone sealant to the transfer case mating surfaces.
    • Use Black Non-Acid Cure Silicone Rubber E7TZ -19562-A or equivalent meeting Ford specification ESL-M4G273-A.
  34. Position the two transfer case halves, and tighten the bolts in the sequence shown in the illustration.
    Fig 33: Positioning Two Transfer Case Halves
    G03444809Courtesy of FORD MOTOR CO.
    35. NOTE: Lift up on the output shaft while installing the snap ring.
    Fig 34: Installing Snap Ring
    G03444810Courtesy of FORD MOTOR CO.
  35. Install the snap ring.
  36. Install the tone wheel and the tone wheel spacer.
    Fig 35: Installing Tone Wheel And Tone Wheel Spacer
    G03444811Courtesy of FORD MOTOR CO.
    37. CAUTION: Applying too much silicone sealant can plug the fluid filter and cause transfer case failure.
    Fig 36: Applying Small Bead Of Sealant To Transfer Case And Extension Housing Mating Surfaces
    G03444812Courtesy of FORD MOTOR CO.
  37. Apply a small bead of sealant to the transfer case and the extension housing mating surfaces.
    • Use Black Non-Acid Cure Silicone Rubber E7TZ -19562-A or equivalent meeting Ford specification ESL-M4G273-A.
  38. Install the extension housing.
    1. Pull the wire through the extension housing.
    2. Position the extension housing.
    3. Install the bolts.
    Fig 37: Installing Extension Housing
    G03444813Courtesy of FORD MOTOR CO.
  39. Using the special tool, install the oil seal if removed.
    Fig 38: Installing Oil Seal
    G03444814Courtesy of FORD MOTOR CO.
    40. CAUTION: Make sure the sensor seats flat against the boss.
    Fig 39: Installing Rear Output Shaft Speed Sensor
    G03444815Courtesy of FORD MOTOR CO.
  40. Install the rear output shaft speed sensor.
    41. CAUTION: Make sure the sensor seats flat against the boss.
    Fig 40: Installing Front Output Shaft Speed Sensor
    G03444816Courtesy of FORD MOTOR CO.
  41. Install the front output shaft speed sensor.
  42. Install the transfer case shift motor.
    Fig 41: Installing Transfer Case Shift Motor
    G03444817Courtesy of FORD MOTOR CO.
  43. Install the front and rear output shaft speed sensor wire pins in the locations noted during their removal.
    Fig 42: Installing Front And Rear Output Shaft Speed Sensor Wire Pins
    G03444818Courtesy of FORD MOTOR CO.
  44. Install the coil wire pin in the electrical connector.
    1. Install the coil wire pin.
    2. Install the wire connector spacer.
    Fig 43: Installing Coil Wire Pin In Electrical Connector
    G03444819Courtesy of FORD MOTOR CO.
  45. Remove the transfer case from the special tool.
    Fig 44: Removing Transfer Case From Special Tool
    G03444820Courtesy of FORD MOTOR CO.
  46. Install the transfer case in the vehicle. For additional information, refer to TRANSFER CASE  .
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