Assembly

Assembly





1. CAUTION: Do not crush the seal.

Use the special tool to install the electric shift motor seal, if equipped.





2. CAUTION: Do not crush the seal.

Use the special tool to install the shift lever seal, if equipped.





3. Note: Access the shift lever set screw through the 4WD indicator switch hole, if equipped.

Tighten the shift lever set screw.





4. Install the shift lever (from outside of case), shift cam and spring, if equipped.





5. Using a suitable press and the special tools, install the front output shaft bearing.





6. Using the special tool, install the front yoke to flange seal.





7. Install the dust shield, if removed.





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





9. Install the front planet carrier bearing snap ring.





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





11. CAUTION: Do not crush the needle bearings.

If removed, using a suitable press and the special tool, install the needle bearing and bushing into the front planet carrier.





12. If removed, using a suitable press, install the front planet support bearing.





13. Install the snap ring.





14. Install the front planet carrier.
1 Position the front planet carrier.
2 Install the front planet carrier snap ring.





15. Using the special tools, install the input seal.





16. Install the electric shift cam assembly, if equipped.





17. Install the shift fork and the reduction hub.





18. Install the shift fork shaft.





19. Install the oil pump and the output shaft.





20. Install the magnet into its slot in the case.





21. Install the drive chain and sprocket assembly.





22. Install the spacer.





23. Note: If the lockup hub assembly was disassembled, perform the following steps.

Assemble the lockup hub assembly.
1 Position the lockup collar.
2 Install the lockup collar springs.
3 Install the lockup hub.
4 Install the armature.
5 Install the lockup hub snap ring.





24. Install the lockup hub and the shift fork and spring.





25. Install the coil housing.





26. Install the bearing and snap ring.





27. Using the special tool, install the rear output shaft bearing.





28. Using the special tool, install the front output shaft bearing.





29. Install the coil.
1 Position the coil.
2 Install the nuts.

30. CAUTION: If too much silicone rubber is used when sealing the cover to case, the excess sealant may plug the fluid filter and cause case failure.

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





31. Position the two transfer case halves and tighten the bolts according to sequence.





32. Install the rear output shaft snap ring.
^ Lift up on the output shaft while installing the snap ring.





33. Install the speed sensor tone wheel, if equipped.





34. 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.





35. Install the extension housing.
1 Position the brown clutch coil wire through its hole in the extension housing.
2 Position the extension housing.
3 Install the extension housing bolts.





36. Using the special tool, install the oil seal if removed.





37. Install the output shaft speed sensor, if equipped.





38. Install the transfer case shift motor, if equipped.





39. Install the coil wire into the shift motor electrical connector. 1 Install the coil wire and pin.
2 Install the wire connector spacer.





40. Remove the transfer case from the special tool.





41. Install the 4WD indicator switch, if equipped.
42. Install the transfer case in the vehicle.