Assembly

1. Using the special tool, install the yoke to flange seal.





2. Using a suitable press and the special tools, install the bearing.





3. Install the front output shaft.
1. Install the front output shaft using a soft-face hammer.
2. Install the snap ring.





4. Install the damper snubbers.





5. Using the special tools, install the bushing if removed.





6. Install the input shaft assembly.





7. Using the special tool, install the yoke to flange seal.





8. Assemble the overdrive sun gear, the upper drive sprocket and the viscous coupling.





9. Using a suitable press and bearing plate, and the special tools, install the bearing on the overdrive sun gear.





10. Place the viscous coupling with the upper and lower drive sprockets and the drive chain in the transfer case.





11. Install the thrust washer.





12. Install the front planetary gear assembly.





13. Install the thrust washer.





14. Attach the ring gear to the upper output shaft, and install the snap ring.





15. Install the upper output shaft and ring gear in the rear case half.
1. Install and expand the snap ring.
2. Install the upper output shaft and the ring gear.
3. Release the snap ring.





16. Install the bearing and the snap ring.





17. Install the bearing.





18. Using the special tool, install the yoke to flange seal.





19. CAUTION: Applying excess silicone rubber can damage the internal components.

Apply a 3 mm (0.125 inch) bead of Black Acid Cure Silicone Rubber F4AZ-19562-B or equivalent meeting Ford specification WSE-M4G323-A1 on the front case mating surface.





20. Assemble the front and rear case halves.





21. Install the 17 bolts.





22. Install the output flange.
1. Position the output flange.
2. Position the oil seal.
3. Position the output shaft yoke washer.
4. Position the nut.





23. While holding the flange with the special tool, tighten the nut.





24. Tighten the drain plug.





25. Remove the fill plug, and fill the transfer case to the bottom of the fill hole.
- Use Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX, XT-2-DDX or equivalent MERCON fluid.





26. Install the fill plug.