Overhaul

Transfer Case Assembly and Disassembly

Special Tool(s) Required:

Disassembly

1. Remove the transfer case (7A195) from vehicle.
2. Remove the transfer case drain plug with a 3/8 inch drive ratchet and drain the fluid.














3. Remove the four wheel drive indicator switch.
4. Using a 30mm thin wall socket, remove the rear output nut, output shaft yoke washer (7B368), rubber seal and case yoke (7B214).
5. Using a 30mm thin wall socket. remove the front output shaft nu, output shaft yoke washer, rubber seal and case yoke.

Caution: When removing RTV sealant, take care not to damage the mating surfaces of the aluminum case.

6. Remove the nine 10mm bolts (7A443) which retain the front case (7005) to the rear case. Remove the wiring harness bracket. Insert a 1/2 inch drive breaker bar between the three pry bosses and separate the front case from the rear case. Remove all trances of RTV gasket sealant from the mating surfaces of the front case and rear case.
7. If the speedometer drive gear (17285) or bearing (7025) is to be replaced, remove the yoke to flange seal (7B215) by prying and pulling on the curved-up lip of the seal or use the Impact Slide Hammer T50T-100-A to pop off the yoke to flange seal. Take care not to damage the bearing, bearing cage or case.






8. Remove the internal snap ring that retains the bearing in the bore. From the outside of the case, drive out the bearing using Step Plate D80L-630-4 or equivalent with a suitable drift.






9. If required, remove the front needle bearing from the rear case with Collet D80L-100-S or equivalent and Impact Slide Hammer T50T-100-A.






10. Remove the 2W-4W shift fork lockup return spring from the boss on the 2W-4W shift fork.






11. Remove the lockup hub from the output shaft. Remove the 2W-4W shift fork together as assembly. Remove the 2W-4W fork from the 2W-4W lockup assembly.






12. If required, disassemble the 2W-4W lockup, remove the internal snap ring and pull the lockup collar and spring from the lock up sleeve.
13. Remove the external snap ring and thrust washer (7119) that retains the driven sprocket to the front output shaft.






14. Remove the chain, driven sprocket and drive sprocket as as assembly.
15. Remove the oil pan magnet (7L027) from the slot in the front case bottom.






16. Remove the rear output shaft and oil pump as as assembly.

Caution: If there is removal resistance, do not pound or use force to disassemble the pump; start over again.

17. If required, rotate the pump to align the cover keyway to shaft pin of the output shaft and pull the pump assembly straight tool.
18. If necessary to replace the oil pump driven pin, perform the following:
- Measure and record the drive pin height above the output shaft diameter. The information is required for installing the new driven pin.
- Remove the drive pin from the output shaft.
19. Remove the front output shaft.
20. Pull out the shift rail.






21. Slip the high-low range shift fork out of the inside track of the shift cam and remove the high-low shift fork and reduction hub together.
22. Push and pull out the anchor of the assist spring from the locking post in the front case half. Remove the assist spring and roller out of the shift cam.
23. Turn the front case over and remove the six 10mm bolts retaining the main drive gear bearing retainer (7050) to the front case. Remove the main drive gear bearing retainer, input shaft (7017) and front planet (7A398) as an assembly.
24. Expand the tangs of the large snap ring in the main drive gear bearing retainer. With the input shaft against a bench, push the main drive gear bearing retainer down and slide it off the bearing. Lift the input shaft and front planet from the main drive gear bearing retainer.






25. If required, remove the yoke to flange seal from the main drive gear bearing retainer by prying and pulling on the curved-up lip of the yoke to flange seal or use the Impact Slide Hammer T50T-100-A to pop off the yoke to flange seal. Do not damage the bearing, bearing cage or case.
26. Remove the internal snap ring from the planetary carrier and separate the front planet from the input shaft.






27. Remove the external snap ring from the input shaft. Place the input shaft in a press and remove the bearing from the input shaft using Bearing Pulling Attachment D79L-4621-A or equivalent. Remove the thrust washer, thrust plate and sun gear off the input shaft.
28. Inspect the bushing and needle bearing in the end of the input shaft for wear or damage.

Note: Under normal use, the needle bearing and bushing should not require replacement. If replacement is required, the bushing and needle bearing must be replace as a set






29. If replacement of the needle bearing and bushing is required, press the bearing and bushing out as follows.
a. Position the input shaft on Support Plate T75L-1165-B and Pinion Bearing Cone Replacer T53T-4621-C as a spacer.
b. Insert Input Shaft Bearing Remover T91T-7127-A into the input shaft so it is resting on top of the bearing cage.
c. Tighten the actuator pin until it stops, then press the bearing and bushing out together.
30. Move the shift lever by hand down to the 4L position, then up two detents to the 4H position. Mark a line on the outside of the front case using the side of the shift lever and a grease pencil.






31. Remove the two Torx head bolts from the front case and from shift cam.

Note: Do not pound on the external clip during removal.

Note: The shift lever and shift cam do not have to be disassembled unless the parts have to replaced.

32. Turn the front case over and remove the C-clip. With the aid of a screwdriver, pry the shift shaft out of the front case and shift cam,
33. Remove the O-ring from the second groove in the shift shaft and discard O-ring.






34. Remove the detent plunger and detent spring from the inside of the front transfer case.
35. If required, remove the ring gear (7A153) from the front case half using press. Note the relationship of the serrations to be chamfered pilot diameter during removal.
36. If required, remove the front yoke to flange seal by prying and pulling on the curved-up lip of the yoke to flange seal or use Impact Slide Hammer T50T-100-A to pop off the yoke to flange seal. Do not damage the bearing, bearing cage or case.






37. If required, remove the internal snap ring and drive the bearing out of the front case bore using Step Plate P80L-630-A or equivalent with a drift.

Assembly

1. If removed, drive the bearing into the front output case bore using Output Shaft Bearing Replacer T83T-7025-B and Driver Handle T80T-4000-W. Drive the bearing in straight, making sure that it is not cocked in the bore. Install the internal snap ring that retains the bearing to the front case.
2. If removed, install the front yoke to flange seal in the front case bore using Output Shaft Seal Replacer T83T-7065-B and Driver Handle T80T-4000-W.






3. If removed, install the ring gear in the front case. Align the serrations on the outside diameter of the ring gear to the serrations previously cut in the front case bore. Using a press, start the piloted chamfered end of the ring gear first and press in until it is fully seated. Make sure the ring gear is not cocked in the bore.
4. Install the detent spring and the detent plunger into the bore from the inside of the front case.

Note: Use a rubber band to fill the first groove so as not to cut the O-ring. Discard the rubber band.

5. Fill the second groove of the shift shaft with Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B and install a new O-ring.






6. After the shift shaft and C-clip have been installed in the front case and with the shift shaft positioned in the 4H detent position place the assist spring roller into part-position on the 90 degree bent tang of the assist spring (Views D and E) and insert the assist roller into the assist spring/roller slot of the shift cam (Views A and B). Position the middle section of the assist spring into the groove of the front case pivot boss (Views C and D) and push to lock the upper end of the assist spring behind the front case spring anchor tab (Views C and D).
7. Install the two Torx head bolts in the front case and in the shift cam. Tighten the screws to 77 - 10 Nm ( 60 - 84 lb in ). Make sure that bolt in the front case is in the first groove of the shift shaft and not bottomed against the shaft itself. The shift shaft should be able to move freely at all detent positions.

Note: The sun gear recessed faced and the snap ring groove on the bearing outer race should be toward the rear of the transfer case. The stepped face of the thrust washer should face toward the bearing.






8. Slide the sun gear, thrust plate, and thrust washer into position on the input shaft. Press the bearing over the input shaft and install the external snap ring to the input shaft.
9. Install the front planet to the sun gear and input shaft. Install the internal snap ring to the planetary carrier.






10. If removed, install the yoke to flange seal into the mounting adapter bore using Output Shaft Seal Replacer T83T-7065-B and Driver Handle T80T-4000W.

Note: If the input shaft needle bearing and bushing were removed, install a new bearing and bushing as detailed in the following steps.
11. Press a new needle bearing, then a new bushing in the input shaft as follows:
a. Position the input shaft on Support Plate T75L-1165-B or equivalent and Pinion Bearing Cone Replacer T53T-4621-C as a spacer.






b. Using Input Shaft Bearing Replacer T91T-7127-B press a new needle bearing into the end of the input shaft until it seats in the input shaft.






c. Press in a new bushing using Input Shaft Bearing Replacer T87T-7127-A.
12. Place the tanged snap ring in the groove of the main drive gear bearing retainer. Using Support Plate T75L-1165-B, place the input shaft and front planet in the main drive gear bearing retainer and expand the tanged snap ring while pushing inward until the front planet and input shaft are seated in the main drive gear bearing retainer. When properly seated, the tanged snap ring will snap into place. Check installation by holding the main drive gear bearing retainer by hand and carefully tapping the face of the input shaft against a wooden block to make sure that the snap ring in engaged.






13. Remove all traces of RTV gasket sealant from the mating surfaces of the front case and main drive gear bearing retainer. Install a bead of RTV gasket sealant on the surface of the front case. Use Black Non-Acid Cure Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M4G273-A.
14. Position the main drive gear bearing retainer on the front case. Install six bolts and tighten to 31 - 41 Nm ( 23 - 30 lb ft ).

Note: Make sure the nylon wear pads are installed on the shift fork and snapped securely into place.

15. Install the high-low shift fork and reduction hub on the output shaft together, and slip the high-low shift fork roller bushing into the high-low of the shift cam.






16. Install the shift rail through the high-low fork and make sure the shift rail is seated in the bore in the front case. Using the shift lever, position the high-low shift fork in the 4H position.
17. If removed press a new pin into the rear output shaft pin hole to the same height or 1 mm (0.040 inch) (minimum) above the diameter of the rear output shaft.

Note: Do not disassemble oil pump, as it is serviced only as an assembly.

Note: Do not remove the plastic inserts from the bore of the new pump. Discard it after it slides out during pump installation to the output shaft.

Note: While turning the output shaft, prime the pump through the oil filter pick-up tube or housing inlet hole with clean MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or DDX or equivalent MERCON fluid.






18. If pump does not turn freely after installation to the output shaft, re-align the cover keyway to pin of the output shaft and jiggle the pump until it fully seats and rotates freely.

If a new pump is used, slide the pump housing slot onto the pin of the output shaft with the retaining arm of the pump cover toward the rear of the case. If the pump dies not rotate freely, follow the direction in the above paragraph.

Inspect the outside surfaces and bore of the oil pump. If there is no discoloration in the pump housing, gear or cover, and the pump bore and the lube holes of the output shaft show evidence of oil, the pump is working. Hand align the keyways and the bores of the housing, gear and cover and slide the pump onto the pin of the output shaft with the retaining arm of the cover toward the rear of the case.

20. Install the output shaft and oil pump in the input shaft. Make sure the external splines of the output shaft engage the internal splines of the lockup hub. Make sure the oil pump retainer arm and oil filter leg are in the groove and notch of the front case.
19. Install the oil pan magnet in the slot in the front case just above the oil filter leg.
21. Install the front output shaft in the front case.

Note: The driven sprocket (on the output shaft) must be installed with the marking "REAR" facing toward the rear case, if so marked.

22. Install the chain, drive sprocket and driven gear sprocket as an assembly over the output shafts.






23. Install the thrust washer on the front output shaft and install a new external snap ring over the thrust washer to retain the driven sprocket.






24. If disassembled, assemble the 2W-4W lockup assembly. Install the spring in the lockup sleeve. Place the lockup collar over the spring and engage the lockup collar in the notches in the lockup sleeve. Retain the lockup sleeve with an internal snap ring.
25. Install the 2W-4W shift fork and lockup over the output shaft and onto the shaft rail.
26. Install the lockup hub to the output shaft.






27. If removed, drive the caged needle bearing into the rear case bore with Needle Bearing Replacer T83T-7127-A and Drive Handle T80T-4000-W.
28. If removed, install the bearing in the rear case bore. Drive the bearing into the rear case bote with Output Shaft Replacer T83T-7025-B and Driver Handle T80T-4000-W. Make sure the bearing is not cocked in the bore.






29. Install the internal snap ring that retains the bearing to the case.
30. Prior to the final assembly of rear case to front case half, the transfer case shift shaft should be shifted into the 4H detent position to ensure positioning of the shift rail to the rear case.
31. Coat the meeting surface of the front case with a bead of Black Non-Acid Cure Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M4G273-A.
32. Install the lockup return spring to the shift rail and shift fork with lockup spring mounted in a vertical position.

Note: If the rear case does not sear properly, move the rear case up and down slightly to permit the end of the shift rail to enter the shift rail hole in the rear case boss or tap the output shaft with a sharp blow using a rubber mallet in a direction away from the output shaft while pushing down on the rear case.

33. Position the rear case so that the spring boss engages the lockup return spring and shift rail. Install the nine bolts starting with the bolts on the rear case. Install the wiring harness bracket. Tighten bolts to 31 - 41 Nm ( 23 - 30 lb ft ).






34. Install the speedometer drive gear into the rear case bore. Drive the yoke to flange seal into the rear case bore with the Output Shaft Seal Replacer T83T-7065-B and Driver Handle T80T-4000-W.
35. Install the rear case yoke on the output shaft. Install the rubber seal, output shaft yoke washer and lock nut. Tighten nut to 339 - 380 Nm ( 250 - 280 lb ft ).
36. Install the front case yoke, rubber seal, output shaft yoke washer and locknut to the output shaft. Tighten nut to 203 - 244 Nm ( 150 - 180 lb ft ).
37. Install the four wheel drive indicator switch with Teflon tape and tighten to 35 - 48 Nm ( 26 - 35 lb ft .
38. Install the drain plug and tighten to 19 - 30 Nm ( 14 - 22 lb ft ).
39. Place a 3/8 inch drive ratchet in the fill plug and remove the plug. Fill the transfer case with 1.2 liters (2.5 U.S. pints) of Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent MERCON fluid. Install the fill plug and tighten to 19 - 30 Nm ( 14 - 22 lb ft ).
40. Install the transfer case.