Assembly
1. Install a new support O-ring seal.
2. Note: Prior to assembly, coat the threads with Pipe Sealant with Teflon(R) D8AZ-19554-A or equivalent meeting Ford specification ESR-M18P7-A.
Using the Sector Shaft Nut Socket, install the sector shaft support (motor adapter for electric shift transfer case).
3. Install the sector assembly. On the electric shift transfer case, install the plastic retainer and O-ring.
4. On the manual shift transfer case, install the spacer, lever, washer and the locknut.
5. Note: If the poppet spring is being replaced, a like color spring must be used.
Assemble the poppet screw, spring and poppet.
6. Install the poppet assembly.
7. Install the rear input gear thrust washer.
8. Install the front input gear thrust washer.
9. Note: Install the lock plate with the stamped letter E facing outward.
Install the lock plate.
10. Place the input gear into the planetary carrier assembly.
11. Install a new lock plate retaining ring.
12. Using the Input Bearing, Installer, the Handle and a suitable press, install a new front input bearing.
13. Install a new bearing retainer ring.
14. Position the planetary assembly into the front case.
15. Install anew retaining ring.
1. Install the Input Shaft Snap Ring Sleeve.
2. Install a new retaining ring.
16. Using the Input Shaft Seal Installer and the Handle, install a new input seal.
17. Using the Front Output Bearing Installer, the Handle and a suitable press, install a new front output ball bearing.
18. Install a new front output ball bearing retaining ring.
19. Position the front output shaft in the front case.
20. Install a new retaining ring.
1. Install the Front Output Shaft Snap Ring Sleeve.
2. Install anew retaining ring.
21. Using the Output Shaft Seal Installer and the Handle, install a new front output seal.
22. Install a new slinger if previously removed.
^ Using the Flange Slinger Installer and the Pilot, install a new slinger on the front flange.
23. Install the front flange.
^ While using the Companion Flange Holding Tool to prevent the flange from turning, install a new nut.
24. Note: Rotate the sector assembly to the 4-wheel high position for easy installation.
Position the range fork assembly and range shift sleeve in the front case.
25. Position the drive sprocket hub onto the mainshaft.
26. On the electric shift transfer case mainshaft, position the inner ring onto the drive sprocket.
27. On the electric shift transfer case mainshaft, position the middle ring onto the inner ring.
28. On the electric shift transfer case mainshaft, position the outer ring onto the middle ring.
29. Position and rotate the synchronizer hub until it drops into the installed position. Install a new retaining ring.
30. Note: The thin side of the synchronizer sleeve must face upward.
Assemble the mode fork, the shift rail and the synchronizer sleeve.
31. Install the mode fork and shift rail assembly into the front case.
^ Make sure to bottom the shift rail in the case.
32. CAUTION: Install the mainshaft assembly so that the synchronizer strut bears against one of the synchronizer sleeve teeth.
Install the mainshaft.
33. Install the clutch gear.
34. Install the drive sprocket, the driven sprocket and the drive chain as an assembly.
35. Install the mode spring.
36. Install a new drive sprocket retaining ring.
37. Install a new driven sprocket retaining ring.
38. Using the Rear Output 13earing Installer, the Handle and a suitable press, install a new ball bearing.
39. Install a new ball bearing retaining ring.
40. Note: The identification numbers must face the driver while installing.
Using the Output Shaft Rear Bearing Installer, the Handle and a suitable press, install a new needle bearing.
41. Install the chip collector magnet.
42. Install the oil tube.
43. Clean both case mating surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A.
44. Note: The silicone bead must be no larger than 2.8 mm (0.08 inch) in diameter.
Apply a bead of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4 to the joint face of the case.
^ The bead must be on the inside of the bolt holes, toward the inside of the case.
45. Position the rear case half onto the front case half
46. Note: Use a crisscross pattern when tightening the case bolts.
Install and tighten the new case bolts.
47. Install the new retaining ring.
1. Install the Rear Output Shaft Snap Ring Sleeve.
2. Install the new retaining ring.
48. Note: Prior to assembly, make sure the O-ring is in the oil pump pickup inlet.
Slide the oil pump assembly onto the mainshaft and connect the oil tube.
49. Note: The identification numbers must face the driver while installing.
Using the Extension Needle Bearing Installer, the Handle and a suitable press, install a new needle bearing.
50. Clean the case and rear retainer mating surfaces with Metal Surface Cleaner F4AZ1.9A536-RA or equivalent meeting Ford specification WSE-M513392-A.
51. Apply a bead of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4 to the rear retainer joint face.
^ The bead must be on the inside of all but one of the bolt holes.
52. Position the rear retainer onto the rear case.
53. Install the eight new retaining bolts.
54. Using the Outer Shaft Seal Installer, install a new rear output seal.
55. Install a new slinger if previously removed.
^ Using the Flange Slinger Installer and the Pilot, install a new slinger.
56. Install the rear flange.
^ While using the Companion Flange Holding Tool to prevent the flange from turning, install a new nut.
57. CAUTION: Do not use air tools.
Install the drain and fill plugs.
58. Note: Apply a coat of Multi-Purpose Grease DOAZ19584-AA or equivalent meeting Ford specification ESB-M1C93-B to the motor adapter.
On the electric shift transfer case, install the gearmotor encoder assembly.
59. On the manual shift transfer case, install the 3 position switch.
60. Tighten the lever nut.