Assembly

1. CAUTION: Do not crush the seal.

Using the special tools, install the shifter shaft seal.





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





3. Using the special tool, install the oil seal.





4. Using the special tool, install the oil seal.





5. Install the front output shaft and flange and snap ring.





6. Install the ring gear, if removed.
1. Position the ring gear.
2. Install the snap ring.





7. CAUTION: Do not crush the bearing cage.

If removed, using a suitable press and the special tool, install the bushing and the bearing.





8. If removed, using a suitable press, install the planetary gear carrier support bearing.





9. Install the snap ring.





10. Install the front planetary gear set assembly.
1. Expand the snap ring.
2. Position the front planetary gear set assembly, and release the snap ring.





11. Install the shift rail.





12. Install the reduction shift fork and the high-low collar as an assembly.





13. Install the electric shift cam assembly.





14. Install the pump assembly and the rear output shaft as an assembly.





15. Install the thrust washer.





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





17. Install the drive chain and sprockets as an assembly.





18. Install the tone wheel.





19. 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 it in place. If the thrust washer is not in place, a transfer case clearance problem can occur.

Install the clutch pack assembly.





20. CAUTION: Use a new snap ring.

Install a new snap ring.





21. Install the wave spring.





22. Install the apply cam and balls.
1. Install the apply cam.
2. Install the steel balls.





23. Install the cam and coil housing.





24. Install the thrust bearing.





25. Install the snap ring.





26. Using a suitable press and the special tools, install the front output shaft rear bearing, and install the rear output shaft support bearing.





27. Position and support the clutch coil assembly, and install the nuts.

28. CAUTION: Applying too much silicone sealant can plug the fluid filter and cause transfer case failure.

Note: Make sure the transfer case mating surfaces are clean.

Apply a 3-mm (1/8-inch) bead of sealant to the transfer case mating surfaces.
- Use Black Non-Acid Cure Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M4G273-A.
29. Position the transfer case halves together.





30. Install the bolts, and tighten them in the specified order.
31. Install the tone wheel.





32. Install the spacer.





33. Install the oil seal.





34. Note: Align the index-marks made during disassembly. Install the rear output flange.
1. Position the flange.
2. Position the oil seal.
3. Position the output flange yoke washer.
4. Install the nut.





35. While holding the flange with the special tool, tighten the nut.





36. CAUTION: Make sure the sensor seats flat against the boss.

Install the front output shaft speed sensor.





37. CAUTION: Make sure the sensor seats flat against the boss.

Install the rear output shaft speed sensor.





38. Note: Make sure the motor mounting surfaces are clean.

Apply a 3-mm (1/8-inch) bead of sealant to the motor mounting surface on the case.
- Use Black Non-Acid Cure Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M4G273-A.





39. Install the transfer case shift motor.





40. Install the front and rear output shaft speed sensor wire pins in the locations noted during their removal.





41. Install the coil wire pin in the electrical connector.
1. Install the coil wire pin.
2. Install the connector interlock.





42. Remove the transfer case from the special tool.

43. Install the transfer case in the vehicle.