Assembly

1. On electrical shift transfer case, install the electric shift motor seal.
^ Use the Seal Replacer.





2. On manual shift transfer case, install the shift lever seal.
^ Use the Seal Replacer.





3. On the manual shift transfer case, install the shift lever (from outside of case), shift cam and spring.





4. Tighten the shift lever set screw.

NOTE: On manual shift transfer case, access the shift lever set screw through the 4WD indicator switch hole.





5. Install the front output shaft bearing.
^ Use the Driver Handle and the Bearing Replacer.





6. Install the front planet carrier bearing.
1 Install the front planet carrier bearing.
^ Use the Dust Shield Replacer and the Driver Handle.
2 Install the front planet carrier bearing snap ring.





7. If removed, install the bushing and needle bearing into the front planet carrier.
^ Use the Input Shaft Bearing Replacer.





8. Install the front yoke to flange seal.
^ Use the Seal Replacer.





9. Install the front output shaft.
1 Position the front output shaft.
2 Install the front output shaft snap ring.





10. Install the ring gear.
1 Position the ring gear.
2 Install the ring gear snap ring.





11. Install the front planet carrier.
1 Position the front planet carrier.
2 Install the front planet carrier snap ring.





12. Install the input seal.
^ Use the Seal Replacer and the Seal Protector.





13. On electrical shift transfer case, install the electric shift cam assembly.





14. Install the shift fork and the reduction hub.





15. Install the shift fork shaft.
16. Install the oil pump onto the output shaft.





17. Install the oil pump and the output shaft.





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





19. Install the drive chain and sprocket assembly.





20. Install the spacer.





21. Assemble the lockup hub assembly.
1 Position the lockup collar.
2 Install the lockup collar springs.
3 Install the lockup hub.
4 Install the armature.
5 Install the lockup hub snap ring.

NOTE: If the lockup hub assembly was disassembled, perform the steps as shown.





22. Install the lockup hub and the shift fork and spring.





23. Install the coil housing.
24. Install the shift collar hub.
^ Install the shift collar hub snap ring onto the rear output shaft.





25. Install the rear output shaft bearing.
^ Use the Center Bearing Replacer and the Driver Handle.





26. Install the front output shaft bearing.
^ Use the Center Bearing Replacer and the Driver Handle.





27. Install the coil.
1 Position the coil.
2 Install the nuts.

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

CAUTION: If too much silicone rubber is used when sealing the cover to case, the excess sealant may plug the fluid filter and cause case failure.





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





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





31. Install the speedometer drive gear and steel ball.
1 Slide the speedometer gear onto the output shaft until it touches the case.
2 Position the steel ball.





32. Install the speedometer gear spacer.
1 Lift up on the speedometer gear.
2 Install the speedometer gear 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 Position the brown clutch coil wire through its hole in the extension housing.
2 Position the extension housing.
3 Install the extension housing bolts.





35. Install the Vehicle Speed Sensor (VSS).
1 Position the VSS.
2 Install the VSS bolt.





36. On electrical shift transfer case, install the transfer case shift motor.
1 Position transfer case shift motor.
2 Install the bolts.





37. Install the coil wire into the shift motor electrical connector.
1 Install the coil wire and pin.
2 Install the wire connector spacer.





38. Remove the transfer case from the bench holding fixture.





39. On manual shift transfer case, install the 4WD indicator switch.
40. Install the transfer case in the vehicle.