Assembly

1. Use (B) Bearing Cone Replacer and (A) Driver Handle to install the output shaft support bearing.





2. Use Seal Replacer to install the electric shift motor shaft seal.





3. Use Bearing Cone Replacer and Driver Handle to install the front output shaft bearing.





4. Use Seal Replacer to install the front output shaft seal





5. If necessary, install the bushing and needle bearing from the front planetary gear set carrier.





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





7. Install the planetary carrier bearing.
(1) Install the planetary carrier.
(2) Depress the snap ring.





8. Install the shift fork shaft.





9. Install the reduction shift fork and reduction hub assembly.





10. Install the shift cam assembly.





11. Install the oil pump and the output shaft as an assembly.





12. Install the thrust washer.





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





14. Install the front driveshaft flange.
- Position the flange.
- Install the snap ring.





15. Install the drive chain and sprockets.





16. Install the front tone wheel.





17. Install the clutch pack assembly.

CAUTION: When removing or installing the clutch pack assembly, do not separate the clutch pack assembly. Keep tension on the clutch pack upon removal. Set the clutch pack assembly on the bench in the same position as it was 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.





18. Install the clutch pack assembly snap ring.

CAUTION: Use new snap ring.





19. Install the wave spring.





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





21. Install the cam coil housing.





22. Install the thrust bearing.





23. Use (A) Driver Handle and (B) Bearing Replacer and install the (C) output shaft support bearing.
- Install the snap ring.





24. Install the electromechanical coil nuts.
- Support the coil while installing the nuts.

CAUTION: Install three aluminum isolator washers between case and three electromechanical coil nuts.

25. Position the transfer case halves.

NOTE: Clean transfer case mating halves; use a 3 mm ( 1/8 in) bead of Black Non-Acid Cure Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M4G273-A on the mating surfaces of the transfer case half.





26. Install the seventeen bolts and tighten in order.
27. Install the rear tone wheel.





28. Install the speedometer drive gear.





29. Install the rear transfer case flange seal.





30. Install the rear transfer case flange.
(1) Position the flange.
(2) Position the flange seal.
(3) Position the flange washer.
(4) Install the flange nut.

NOTE: Align marks made on disassembly.





31. Using Companion Flange Holding Tool tighten the rear output flange nut.





32. Install the front output shaft tone wheel sensor.
(1) Position the sensor.
(2) Install the bolt.





33. Install the rear output shaft tone wheel sensor.
(1) Position the sensor.
(2) Install the bolt.





34. Install the electric shift motor.
(1) Clean shift motor mounting surface on case and position the electric shift motor using a 3 mm (1/8 in) bead of Black Non-Acid Cure Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M4G273-A on the shift motor mating surface of the case.
(2) Install the bolts.





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





36. Remove the transfer case from Bench Mounted Holding Fixture.
37. Install the transfer case in the vehicle.