Assembly

1. Use Seal Installer to install the shift motor seal.





2. Install the front output shaft seal.





3. Use (A) Driver Handle and (B) Bearing Installer to install the (C) front output shaft seal.





4. Use (A) seal installer and (B) seal protector to install the output shaft seal.





5. Install the planetary gear bearing snap ring.





6. Install the ring gear.
(1) Position the ring gear.
(2) Install the ring gear snap ring.





7. If removed, use input shaft bearing installer to install the bushing and needle bearing into the planetary gear set.





8. Install the planetary gear support bearing.
(1) Position the bearing on the planetary gear set.
(2) Install the snap ring.





9. Install the planetary gear set.
(1) Position the gear set.
(2) Depress the snap ring.

NOTE: The planetary gear set needs to be rotated for correct positioning on the transfer case.





10. Install the front output shaft.
(1) Position the front output shaft.
(2) Install the front output shaft snap ring.

NOTE: Support the front output shaft during installation.





11. Install the shift cam assembly.





12. Install the shift fork shaft.





13. Install the reduction shift fork and the reduction hub.





14. Install the oil pump and output shaft as a assembly.





15. Install the magnet into its slot in the case.





16. Install the lockup hub and lockup shift fork assembly.





17. Install the drive chain and sprockets.





18. Install the three-piece thrust bearing assembly (non-directional).
(1) Install the thrust bearing race.
(2) Install the thrust bearing.





19. Install the tone wheel (front output shaft).





20. Install the clutch pack assembly.

CAUTION: When removing or installing the clutch assembly, do not separate the clutch pack assembly. Set the clutch pack assembly on the bench in the same position as located in the transfer case. The thrust washer in the lower clutch pack uses tabs to hold in place. If the thrust washer is not in place, a transfer case clearance problem may occur.





21. Install the clutch pack assembly snap ring.





22. Install the wave spring.





23. Install the cam assembly.
(1) Install the cam plate assembly.
(2) Install the steel balls.





24. Install the cam/coil housing.





25. Install the thrust bearing assembly.
(1) Install the thin thrust bearing race.
(2) Install the thrust bearing.
(3) Install the thick thrust bearing race.





26. Install the output shaft thrust bearing snap ring.





27. Install the coil in the transfer case.
(1) Position the coil in the case.
(2) Tighten the coil nuts.

28. Coat the two mating surfaces of the transfer case halves with a small bead of silicone sealant.
- Use Black Non-Acid Cure Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M4G273-A.

CAUTION: If too much silicone sealant is used when sealing the transfer case halves, the excessive sealant may plug the fluid filter and can cause transfer case failure.





29. Position the two transfer case halves and tighten the bolts according to sequence.





30. Install the output shaft snap ring.
- Lift up on the output shaft while installing the snap ring.





31. Install the speedometer drive gear and tone wheel.
(1) Install the tone wheel.
(2) Slide the speedometer gear down against the tone wheel.
(3) Install the steel ball.
(4) Index the speedometer gear according to the steel ball.

NOTE: Use caution when installing the speedometer gear. Avoid damaging the plastic gear grooves.





32. Install the speedometer spacer.





33. Apply a small bead of sealant to the transfer case cover and extension housing mating surfaces.
- Use Black Non-Acid Cure Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M4G273-A.





34. Install the extension housing.
(1) Pull wire through extension housing.
(2) Position the extension housing.
(3) Install the bolts.

CAUTION: If too much silicone sealant is used when sealing the transfer case, the excessive sealant may plug the fluid filter and can cause transfer case failure.





35. Install the extension housing driveshaft seal.
- Use the Extension Housing Seal Installer, and install the seal.





36. Install the output shaft speed sensor.





37. Install the front output shaft speed sensor.





38. Install the electric shift motor.
(1) Position the electric shift motor.
(2) Install the bolts.





39. Install the vehicle speed sensor (VSS).
(1) Position the VSS.
(2) Install the bolt.





40. Install the coil wire in the electric shift motor and electrical connector.
(1) Install the coil wire connector and pin.
(2) Install the wire connector spacer.





41. Remove the transfer case from the bench holding fixture.
42. Install the transfer case in the vehicle.