Assembly

1. Use the Bearing Cap Replacer and the Driver Handle to install the output shaft support bearing.





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





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





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





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





6. Install the planetary gear carrier support bearing.
1 Position the bearing.
2 Install the snap ring.





7. Install the planetary gear carrier.
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 output shaft and flange.
- Position the flange.
- Install the snap ring.





15. Install the drive chain and sprockets.





16. Install the front tone wheel.

17. 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 can occur.





Install the clutch pack assembly.

18. CAUTION: Use new snap ring.





Install the clutch pack assembly 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 the Driver Handle and Bearing Cap Replacer, and install the output shaft support bearing.
- Install the snap ring.

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





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

25. NOTE: Clean the transfer case mating halves; use a 3-mm (1/8-inch) 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.

Position the transfer case halves.





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





28. Install the spacer.





29. Install the rear transfer case flange seal.

30. NOTE: Align marks made on disassembly.





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.





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





32. Install the front output shaft speed sensor.
1 Position the speed sensor.
2 Install the bolt.





33. Install the rear output shaft speed sensor.
1 Position the speed sensor.
2 Install the bolt.





34. Install the transfer case shift motor.
1 Clean the shift motor mounting surface on the case, and position the transfer case shift motor using a 3-mm (1/8-inch) 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 the Bench Mounted Holding Fixture.
37. Install the transfer case in the vehicle.