Assembly

1. Use the Seal Installer to install the shifter shaft seal.





2. Use the Driver Handle and the Bearing Cup Replacer and install the front output shaft bearing.





3. Install the front output shaft seal.





4. Use the Driver Handle and Bearing Installer to install the front output shaft seal.





5. Use the Input Shaft Seal Replacer and Seal Protector to install the input shaft seal.





6. Install the planetary gear bearing snap ring.





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





8. If removed, use the input shaft bearing installer to install the bushing and needle bearing into the front planet.





9. Install the planetary gear support bearing.
1 Position the bearing on the front planet.
2 Install the snap ring.





10. NOTE: The front planet needs to be rotated for correct positioning on the transfer case.

Install the front planet.
1 Position the front planet.
2 Depress the snap ring.





11. NOTE: Support the front output shaft during installation.

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





12. Use the Center Bearing Replacer and the Driver Handle to install the rear output shaft bearing.





13. Use the Center Bearing Replacer and the Driver Handle to install the front input shaft bearing.





14. Install the shift cam assembly.





15. Install the shift fork shaft.





16. Install the reduction shift fork and the reduction hub.





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





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





19. Install the lockup hub and lockup shift fork assembly.





20. Install the drive chain and sprockets.





21. Install the three-piece thrust bearing assembly (non-directional).
1 Install the thrust bearing race.
2 Install the thrust bearing.
3 Install the thrust bearing race.





22. Install the tone wheel (front output shaft).





23. CAUTION: When removing or installing the clutch assembly, do not separate the clutch pack assembly. Set the clutch pack assembly on the bench in the same position as 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 can occur.

Install the clutch pack assembly.





24. Install the clutch pack assembly snap ring.





25. Install the wave spring.





26. Install the cam assembly.
1 Install the cam plate assembly.
2 Install the steel balls.





27. Install the cam/coil housing.





28. Install the thrust bearing assembly.
1 Install the thin thrust bearing race.
2 Install the thrust bearing.
3 Install the thick thrust bearing race.





29. Install the output shaft thrust bearing snap ring.





30. Install the coil in the transfer case.
1 Position the coil in the case.
2 Tighten the coil nuts.

31. CAUTION: If too much silicone sealant is used when sealing the transfer case halves, the excessive sealant may plug the fluid filter and can cause transfer case failure.

Coat the two mating surfaces of the transfer case halves with a small bead of silicone sealant.
- Use Black Non-Acid Cure Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M4G273-A.





32. Position the two transfer case halves, and tighten the bolts in the sequence shown in the illustration.





33. Install the output shaft snap ring.
- Lift up on the output shaft while installing the snap ring.





34. CAUTION: Use caution when installing the speedometer gear. Avoid damaging the plastic gear grooves.

Install the speedometer drive gear and tone wheel.
1 Install the tone wheel.
2 Slide the speedometer gear down against the tone wheel.
3 Install the steel ball.
4 Index the speedometer gear according to the steel ball.





35. Install the speedometer spacer.





36. CAUTION: If too much silicone sealant is used when sealing the transfer case, the excessive sealant may plug the fluid filter and can cause transfer case failure.

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.





37. Install the extension housing.
1 Pull the wire through the extension housing.
2 Position the extension housing.
3 Install the bolts.





38. Install the extension housing driveshaft seal.
- Use the Extension Housing Seal Installer to install the seal.





39. Install the output shaft speed sensor.





40. Install the front output shaft speed sensor.





41. Install the transfer case shift motor.
1 Position the transfer case shift motor.
2 Install the bolts.





42. Install the Vehicle Speed Sensor (VSS).
1 Position the vehicle speed sensor.
2 Install the bolt.





43. 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.





44. Remove the transfer case from the bench holding fixture.
45. Install the transfer case in the vehicle.