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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 special tools, install the front input shaft bearing.
    4. Fig 1: Installing Front Input Shaft Bearing Using A Suitable Press & Special Tools (205-D055, 308-410)
    GF0046975Courtesy of FORD MOTOR CO.
  4. Using a suitable press and the special tools, install the front shaft support bearing.
    5. Fig 2: Installing Front Shaft Support Bearing Using A Suitable Press & Special Tools (205-D055, 205-350)
    GF0046976Courtesy of FORD MOTOR CO.
  5. Using the special tool, install a new front output shaft seal.
    6. Fig 3: Installing Front Output Shaft Seal Using Special Tool (308-186)
    GF0046977Courtesy 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.
  7. Using the special tool, install a new front input shaft seal.
    8. Fig 4: Installing Front Input Shaft Seal Using Special Tool (308-249)
    GF0046978Courtesy of FORD MOTOR CO.
  8. Install the front output shaft and the snap ring.
    9. Fig 5: Identifying Front Output Shaft & Snap Ring
    GF0046970Courtesy of FORD MOTOR CO.
  9. Install the input shaft.
    10. Fig 6: Identifying Input Shaft
    GF0046969Courtesy of FORD MOTOR CO.
  10. Install the output shaft.
    11. Fig 7: Identifying Output Shaft
    GF0046968Courtesy of FORD MOTOR CO.
    NOTE: Make sure the oil pump finger is in the slot in the case.
  11. Install the oil pump assembly.
    12. Fig 8: Identifying Oil Pump Assembly
    GF0046967Courtesy of FORD MOTOR CO.
  12. Install the oil pan magnet into its 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.
    15. Fig 9: Identifying Drive Chain & Sprockets
    GF0046964Courtesy 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 will occur.
  15. Install the clutch pack assembly. Make sure to align the clutch pack with the sprocket.
    16. Fig 10: Identifying Clutch Pack Assembly
    GF0046963Courtesy of FORD MOTOR CO.
  16. Install a new snap ring.
    17. Fig 11: Locating Snap Ring
    GF0022949Courtesy of FORD MOTOR CO.
  17. Install the wave spring.
    18. Fig 12: Identifying Wave Spring
    GF0046961Courtesy of FORD MOTOR CO.
  18. Install the cam and the steel balls.
    19. Fig 13: Identifying Steel Balls & Cam
    GF0046960Courtesy of FORD MOTOR CO.
  19. Install the cam/coil housing.
    20. Fig 14: Identifying Cam/Coil Housing
    GF0046959Courtesy of FORD MOTOR CO.
  20. Install the caged thrust bearing assembly.
    21. Fig 15: Identifying Caged Thrust Bearing Assembly
    GF0046958Courtesy of FORD MOTOR CO.
  21. Install the washer.
    22. Fig 16: Identifying Washer
    GF0046957Courtesy of FORD MOTOR CO.
  22. Install the snap ring.
    23. Fig 17: Inspecting Snap Ring For Wear Or Damage
    GF0046956Courtesy of FORD MOTOR CO.
  23. Using a suitable press and the special tool, install the rear output shaft support bearing.
    24. Fig 18: Installing Rear Output Shaft Support Bearing Using A Suitable Press & Special Tool (308-060)
    GF0046979Courtesy of FORD MOTOR CO.
  24. Using a suitable press and the special tool, install the front output shaft rear bearing.
    25. Fig 19: Installing Front Output Shaft Rear Bearing Using A Suitable Press & Special Tool (308-060)
    GF0046980Courtesy of FORD MOTOR CO.
    CAUTION: Applying too much silicone sealant will plug the fluid filter and cause transfer case failure.
  25. 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).
    26. Fig 20: Applying A Bead Of Silicone Sealant To Transfer Case Mating Surface
    GF0046952Courtesy of FORD MOTOR CO.
  26. Install the 3 coil washers and nuts.
    • Tighten to 10 Nm (89 lb-in).
  27. Using the special tool, install the rear output shaft seal.
    28. Fig 21: Installing Rear Output Shaft Seal Using Special Tool (308-249)
    GF0022970Courtesy of FORD MOTOR CO.
  28. Insert the coil wire pin in the electrical connector and install the inner connector retainer.
  29. Install the connector bracket and the 2 connector bracket bolts.
    30. Fig 22: Identifying Connector Bracket Bolts
    GF0046950Courtesy of FORD MOTOR CO.
  30. Remove the transfer case from the special tool.
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