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Home >> Lincoln >> 2013 >> Navigator Base, RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Transfer Case) >> Disassembly And Assembly >> Transfer Case - 1-Speed Torque-On-Demand >> 1-Speed Transfer Case - Front View >> Assembly
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1-Speed Transfer Case - Front View: Assembly

WARNING: This page is about a different variant/trim than selected.
  1. Lubricate all internal components with the recommended transfer case lubricant during reassembly.
  2. Clean the mating surfaces of the cases.
  3. Using a press and the Output Shaft Front Bearing Installer with the Handle, install the front input shaft bearing.
    Fig 1: Installing Front Input Shaft Bearing
    G06128144Courtesy of FORD MOTOR CO.
  4. Using a press and the Front Axle Oil Seal Installer with the Handle, install the front shaft support bearing.
    Fig 2: Installing Front Shaft Support Bearing
    G06128145Courtesy of FORD MOTOR CO.
  5. Using the Input Shaft Oil Seal Installer, install a new front output shaft seal.
    Fig 3: Installing Front Output Shaft Seal
    G07412676Courtesy of FORD MOTOR CO.
  6. Install the case to the Transmission Holding Fixture. Secure the case and the Transmission Holding Fixture to the work bench.
    Fig 4: Removing Transfer Case From Transmission Holding Fixture
    G06128103Courtesy of FORD MOTOR CO.
  7. Using the Input Shaft Oil Seal Installer, install a new front input shaft seal.
    Fig 5: Installing Front Input Shaft Seal
    G07412681Courtesy of FORD MOTOR CO.
  8. Install the front output shaft and the snap ring.
    Fig 6: Locating Snap Ring And Front Output Shaft
    G06128139Courtesy of FORD MOTOR CO.
  9. Install the driven sprocket spacer.
    Fig 7: Locating Driven Sprocket Spacer
    G07953768Courtesy of FORD MOTOR CO.
  10. Install the input shaft.
    Fig 8: Locating Input Shaft
    G06128138Courtesy of FORD MOTOR CO.
  11. Install the output shaft.
    Fig 9: Locating Output Shaft
    G06128137Courtesy of FORD MOTOR CO.
    12. NOTE: Make sure the oil pump finger is in the slot in the case.
    Fig 10: Locating Oil Pump Assembly
    G06128136Courtesy of FORD MOTOR CO.
  12. Install the oil pump assembly.
  13. Install the oil pan magnet into the slot in the case.
  14. Install the 3-piece thrust bearing assembly: the thrust washer, thrust bearing and thrust washer.
  15. Install the drive chain and the sprockets as an assembly.
    Fig 11: Locating Drive Chain And Sprockets Assembly
    G06128133Courtesy of FORD MOTOR CO.
    16. NOTE: When installing the clutch assembly, do not separate the clutch pack assembly. 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 will occur.
    NOTE: If the clutch pack is disassembled, a new clutch pack must be installed and the armature transferred. Failure to install a new clutch pack can result in component failure.
    Fig 12: Locating Clutch Pack Assembly
    G06128132Courtesy of FORD MOTOR CO.
  16. Install the clutch pack assembly with the armature. Make sure to align the clutch pack with the sprocket.
  17. Install a new snap ring.
    Fig 13: Locating Snap Ring
    G06128062Courtesy of FORD MOTOR CO.
  18. Install the wave spring.
    Fig 14: Locating Wave Spring
    G06128130Courtesy of FORD MOTOR CO.
  19. Install the cam and the steel balls.
    Fig 15: Locating Steel Balls And Cam
    G06128129Courtesy of FORD MOTOR CO.
  20. Install the cam/coil housing.
    Fig 16: Locating Cam/Coil Housing
    G06128158Courtesy of FORD MOTOR CO.
  21. Install the caged thrust bearing assembly.
    Fig 17: Locating Caged Thrust Bearing Assembly
    G06128127Courtesy of FORD MOTOR CO.
  22. Install the spacer.
    Fig 18: Locating Spacer
    G06457323Courtesy of FORD MOTOR CO.
  23. Install the snap ring.
    Fig 19: Locating Snap Ring
    G06128125Courtesy of FORD MOTOR CO.
  24. Using a press and the Mainshaft Bearing Installer, install the rear output shaft support bearing.
    Fig 20: Installing Rear Output Shaft Support Bearing
    G06128162Courtesy of FORD MOTOR CO.
  25. Using a press and the Mainshaft Bearing Installer, install the front output shaft rear bearing.
    Fig 21: Installing Front Output Shaft Rear Bearing
    G06128163Courtesy of FORD MOTOR CO.
    26. NOTE: Only apply enough silicone sealant to seal the transfer case halves together.
  26. Apply a bead of silicone sealant to the transfer case mating surface. Position the 2 transfer case halves together, aligning the coil studs through the case holes. Tighten the 20 transfer case bolts evenly in a star pattern.
    • Tighten to 29 Nm (21 lb-ft).
      Fig 22: Locating Transfer Case Bolt
      G06128056Courtesy of FORD MOTOR CO.
  27. Install the 3 coil washers and nuts.
    • Tighten to 10 Nm (89 lb-in).
  28. Using the Input Shaft Oil Seal Installer, install the rear output shaft seal.
    Fig 23: Installing Rear Output Shaft Seal
    G06128101Courtesy of FORD MOTOR CO.
    29. NOTE: After the wire is inserted into the connector, gently pull the wire back to verify the pin is locked inside the connector.
    Fig 24: Locating Inner Connector Retainer
    G06128118Courtesy of FORD MOTOR CO.
  29. Insert the coil wire pin in the electrical connector and install the inner connector retainer.
  30. Install the connector bracket and the 2 connector bracket bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 25: Locating Connector Bracket Bolts
      G06128119Courtesy of FORD MOTOR CO.
  31. Secure the transfer case to a transmission jack and remove the transfer case from the Transmission Holding Fixture.
    Fig 26: Removing Transfer Case From Transmission Holding Fixture
    G06128103Courtesy of FORD MOTOR CO.
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