Assembly
Assembly
All transfer cases
1. Install a new support O-ring seal.
2. NOTE: Prior to installation, coat the threads with Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2.
Using the special tool, 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 the O-ring.
Manual shift transfer case
4. Install the spacer, the lever, the washer, and the locknut.
All transfer cases
5. NOTE: If installing a new poppet spring, it must be like in color to the original poppet spring.
Assemble the poppet screw, the spring, and the 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 special tools 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 a new retaining ring.
1 Install the special tool.
2 Install a new retaining ring.
^ Remove the special tool.
16. Using the special tools, install a new input seal.
17. Using the special tools 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 special tool.
2 Install a new retaining ring.
^ Remove the special tool.
21. Using the special tools, install a new front output seal.
22. Using the special tools, install a new slinger on the front flange, if removed.
23. Install the front flange.
^ Use the special tool to prevent the flange from turning while installing a new nut.
24. NOTE: Rotate the sector assembly to the 4-wheel high position for easy installation.
Position the range fork assembly and the range shift sleeve in the front case.
25. Position the drive sprocket hub on the mainshaft.
Electric shift transfer case
26. Position the inner ring on the drive sprocket.
27. Position the middle ring on the inner ring.
28. Position the outer ring on the middle ring.
All transfer cases
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 or mode sleeve must face upward.
Assemble the mode fork, the shift rail, and the sleeve.
^ Mode sleeve for mechanical shift or synchronizer sleeve for electric shift.
31. Install the mode fork and the shift rail assembly in the front case.
^ The shift rail must bottom in the case.
32. CAUTION: Install the mainshaft assembly so that the synchronizer strut bears against one of the synchronizer or mode 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 special tools and a suitable press, install a new ball bearing.
39. Install a new ball bearing retaining ring.
40. NOTE: The identification numbers on the bearing must face the special tool.
Using the special tools 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-M5B392-A.
44. NOTE: The silicone bead must be no larger than 2 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 bolts.
Install the 25 new bolts retaining the rear case to the front case.
47. Install the new retaining ring.
1 Install the special tool.
2 Install the new retaining ring.
^ Remove the special tool.
48. NOTE: Prior to assembly, verify that 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 on the needle bearing must face the special tool.
Using the special tools and a suitable press, install a new needle bearing.
50. Clean the rear case and rear retainer mating surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-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 on the rear case.
53. Install the eight new bolts retaining the rear retainer to the case.
54. Using the special tools, install a new rear Output seal.
55. Using the special tools, install a new slinger on the rear flange, if removed.
56. Install the rear flange.
^ Use the special tool to prevent the flange from turning while installing a new nut.
57. CAUTION: Do not use air tools.
Install the drain and fill plugs.
Electric shift transfer case
58. NOTE: Apply a coat of Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specification ESB-M1C93-B to the motor adapter.
Install the gear motor encoder assembly.
Manual shift transfer case
59. Install the 3 position switch.
60. Tighten the nut.
All transfer cases
61. Remove the transfer case from the special tool.