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Transfer Case - AWD: Assembly

  1. Install the front output shaft rear bearing.
  2. Install a new input shaft seal.
  3. Using the special tool, install a new front output shaft yoke-to-flange seal.
    Fig 1: Installing Front Output Shaft Yoke-To-Flange Seal
    G03265509Courtesy of FORD MOTOR CO.
  4. Using the special tools, install the front output shaft bearing.
    Fig 2: Installing Front Output Shaft Bearing
    G03265510Courtesy of FORD MOTOR CO.
  5. Install the front output shaft dust deflector.
  6. Position the front output shaft.
    Fig 3: Installing Front Output Shaft Dust Deflector
    G03265511Courtesy of FORD MOTOR CO.
  7. While holding the front output shaft, install the snap ring.
    Fig 4: Installing Snap Ring
    G03265512Courtesy of FORD MOTOR CO.
  8. Using the special tool, install a new input shaft bearing.
    Fig 5: Installing A New Input Shaft Bearing
    G03265513Courtesy of FORD MOTOR CO.
  9. Install the input shaft.
    Fig 6: Installing Input Shaft
    G03265514Courtesy of FORD MOTOR CO.
  10. Install the clutch assembly.
    Fig 7: Installing Clutch Assembly
    G03265515Courtesy of FORD MOTOR CO.
  11. Install the thrust washer.
    Fig 8: Installing Thrust Washer
    G03265516Courtesy of FORD MOTOR CO.
  12. Assemble the overdrive sun gear, the upper drive sprocket, lower drive sprocket and the drive chain.
    • Align the blind spline on the lower drive sprocket with the narrow spline on the overdrive sun gear.
    Fig 9: Aligning Blind Spline On Lower Drive Sprocket With Narrow Spline On Overdrive Sun Gear
    G03265517Courtesy of FORD MOTOR CO.
  13. Install the overdrive sun gear, the upper and lower drive sprockets and the drive chain.
    Fig 10: Installing Overdrive Sun Gear, Upper And Lower Drive Sprockets And Drive Chain
    G03265518Courtesy of FORD MOTOR CO.
  14. Install the thrust washer.
    Fig 11: Installing Thrust Washer
    G03265519Courtesy of FORD MOTOR CO.
  15. Install the front planetary gear assembly.
    Fig 12: Installing Front Planetary Gear Assembly
    G03265520Courtesy of FORD MOTOR CO.
  16. Install the output shaft thrust washer.
    Fig 13: Installing Output Shaft Thrust Washer
    G03265521Courtesy of FORD MOTOR CO.
  17. Position the 2 damper snubbers, then install the 4 Torx® head screws.
    • Tighten to 7 Nm (62 lb-in).
    Fig 14: Positioning 2 Damper Snubbers
    G03265522Courtesy of FORD MOTOR CO.
  18. Assemble the upper output shaft and the ring gear.
    1. Install the output shaft.
    2. Install the snap ring.
    3. Press on the bearing.
    Fig 15: Assembling Upper Output Shaft And Ring Gear
    G03265523Courtesy of FORD MOTOR CO.
  19. Install the snap ring.
    Fig 16: Installing Snap Ring
    G03265524Courtesy of FORD MOTOR CO.
  20. Install the oil scoop.
    Fig 17: Installing Oil Scoop
    G03265525Courtesy of FORD MOTOR CO.
  21. Install the output shaft support bearing.
    Fig 18: Installing Output Shaft Support Bearing
    G03265526Courtesy of FORD MOTOR CO.
  22. Install the upper output shaft and ring gear in the rear case half.
    • Expand the snap ring. Install the upper output shaft and the ring gear.
    • Release the snap ring.
    Fig 19: Installing Upper Output Shaft And Ring Gear In Rear Case Half
    G03265527Courtesy of FORD MOTOR CO.
  23. Using the special tool, install the yoke-to-flange seal.
    Fig 20: Installing Yoke-To-Flange Seal
    G03265528Courtesy of FORD MOTOR CO.
    24. CAUTION: Applying excess silicone rubber can damage the internal components.
    Fig 21: Applying A 3-mm (0.11-In) Bead Of Silicone Rubber On Rear Case Mating Surface
    G03265529Courtesy of FORD MOTOR CO.
  24. Apply a 3-mm (0.11-in) bead of silicone rubber on the rear case mating surface.
  25. Assemble the front and rear case halves.
    Fig 22: Assembling Front And Rear Case Halves
    G03265530Courtesy of FORD MOTOR CO.
  26. Install the 17 transfer case bolts.
    • Tighten to 25 Nm (18 1b-ft).
  27. Install a new output flange oil seal.
    28. NOTE: Align the index marks made during disassembly.
  28. Install the output flange.
  29. Install the output shaft yoke washer.
  30. Using the special tool to hold the output flange, install the nut.
    • Tighten to 355 Nm (262 lb-ft).
    Fig 23: Installing Nut Using Special Tool To Hold Output Flange
    G03265531Courtesy of FORD MOTOR CO.
  31. Position the damper and install the 4 bolts.
    • Tighten to 22 Nm (16 lb-ft).
  32. Install the transfer case into the vehicle. For additional information, refer to TRANSFER CASE .
  33. Fill the transfer case. For additional information, refer to TRANSFER CASE DRAINING AND FILLING .
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