Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Transfer Case - Vehicles With: Manual Shift Transfer Case: Assembly
- Using the special tools, install the center support bearing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-344 (T95P-7H150-A) Installer, Driven Sprocket Wheel.
- Using the special tools, install the front planet carrier bearing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 308-410 Installer, Output Shaft Front Bearing.
- Using the special tools, install the front output shaft bearing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-626 Installer, Differential Seal.
- Using the special tools, install the front output shaft support bearing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-626 Installer, Differential Seal.
- Using the special tools, install the rear output shaft bearing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 308-410 Installer, Output Shaft Front Bearing.
- Using the special tools, install the input shaft seal. Use Special Service Tool: 205-1018 Installation Tube., 308-943 Installer, Input Seal.
- Using the special tools, install the front output shaft seal. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 308-944 Installer, Front Output Seal.
-
NOTE: Do not let the front output shaft fall while removing the snap ring or damage to the component may occur.
Install the output shaft and the out put shaft circlip.
- Install the manual shift assembly.
- Install the shift guide plate and guide plate spring arm.
- Install the shift lever.
- Tighten the shift lever set screw.
- Install the ring gear and the ring gear circlip.
- Install the planet carrier and the front planet carrier thrust bearing.
- Install the shift fork assembly.
-
NOTE: The pump assembly is not repairable.
Install the magnet and oil pump assembly.
- Install the output shaft.
- Install the center bearing support assembly.
- Install the shift rail.
- Install the drive chain and the sprockets as an assembly.
- Install the lock hub shift fork assembly.
- Install the shift fork lock hub and align shift fork slide grooves.
- Install the shift lock hub snap ring.
-
NOTE: Only apply enough silicone sealant to seal the transfer case halves together.
Apply a small bead of silicone sealant to the mating surface of the case half.
Material: Motorcraft Ā® Ultra Silicone Sealant / TA-29
- Position the transfer case halves and tighten the bolts in the sequence shown.
Torque: 23 lb.ft (31 Nm)
- Install the transfer case rear seal. Refer to: Transfer Case Rear SealĀ .
- Remove the transfer case from the transmission adjustable mounting arms. Use the General Equipment: Adjustable Mounting Arm
NO RELATED
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
Affiliate disclosure: We may earn a commission at no extra cost to you.
When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- ā¢ You smell fuel, burning insulation, or see smoke.
- ā¢ Brakes feel soft, pull hard to one side, or make grinding noises.
- ā¢ The engine overheats, stalls repeatedly, or misfires under load.
- ā¢ You are missing required tools, torque specs, or safe lifting equipment.
- ā¢ You are not confident in the next step or safety outcome.