All Wheel Drive

1. Place the transfer case front half in the Bench Mounted Holding Fixture, and install the front yoke to flange seal with the Front Pump Seal Replacer.





2. Position the Seal Protector.





3. Install the yoke to flange seal with the Seal Replacer Input Shaft.





4. Press the front output shaft bearing with the Bearing Cone Replacer, Differential Seal Replacer, and Driver Handle.





5. Install the front output shaft.
1 Install the front output shaft using a soft-face hammer.
2 Install the retaining ring.





6. Install the two chain snubbers.





7. Install the input shaft.





8. Press the sun gear shaft bearing with the Pinion Bearing Cone Replacer, Bearing Plate, and Bearing Pulling Attachment.





9. Place the viscous clutch with the driven sprocket and the drive chain in the transfer case.





10. Install the output shaft thrust washer.





11. Install the planetary assembly.





12. Install the output shaft thrust washer.





13. Attach the ring gear to the rear output shaft.
1 Position the ring gear on the rear output shaft.
2 Attach the snap ring.





14. Install the rear output shaft and ring gear in the rear case half.
1 Place the rear half of the case in the Bench Mounted Holding Fixture.
2 Install the retaining ring.
3 Install the rear output shaft and ring gear in the retaining ring.





15. Install the speedometer tone wheel and the output shaft bearing.





16. Position the rear output shaft bearing and yoke to flange seal.
1 Put the rear output shaft bearing over the rear output shaft.
2 Position the rear yoke to flange seal on the rear output shaft bearing.





17. Install the rear yoke to flange seal with the Front Pump Seal Replacer.

18. CAUTION: Do not apply excess silicone rubber. Loosened silicone rubber may damage internal components.





Install a bead of Black Acid Cure Silicone Rubber F4AZ-19562-B or equivalent meeting Ford specification WSE-M4G323-Al on the surface of the front case.





19. Assemble the front and rear case halves.





20. Install the 17 bolts from the front and rear case halves.





21. Install the case yoke.
1 Position the case yoke.
2 Position the oil seal.
3 Position the output shaft yoke washer.
4 Position the rear shaft nut.





22. Tighten the rear shaft nut.





23. Install the drain plug.





24. Remove the fill plug.
- Fill the transfer case with Motorcraft MERCON(R) Multi-Purpose Automatic Transmission Fluid XT-2-QDX, XT-2-DDX or equivalent MERCON(R) fluid to the bottom of the fill hole.





25. Install the fill plug.