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: 2-Speed Torque On Demand Transfer Case: Assembly
2021 Ford Edge SE, 4WDSECTION Assembly
WARNING: This page is about a different car, the 2020 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
Lubricate all internal components with the recommended transfer case lubricant during reassembly.
- Using the special tools, install the front planet carrier bearing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 205-504 Installer, Halfshaft Pilot Bearing.
- Using the special tools, install the front output shaft bearing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 205-293 (T89P-4850-A) Installer, Differential Oil Seal.
- Using the special tool, install the front output shaft support bearing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 307-582A Cover Axle Seal Installer.
- Using the special tool, install the rear output shaft bearing. Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 307-582A Cover Axle Seal Installer.
- Using the special tool, install the input shaft seal. Use Special Service Tool: 308-250 (T96T-7127-B) Installer, Output Shaft Oil Seal.
- Using the special tool, install the front output shaft seal. Use Special Service Tool: 308-250 (T96T-7127-B) Installer, Output Shaft Oil Seal.
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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 ring gear.
- If removed, using a press and the special tool, install the needle bearing into the front planet carrier. Use Special Service Tool: 308-085 (T83T-7025-C) Installer, Input Shaft Bearing.
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NOTE: Replace the inner planet carrier needle bearing if necessary.
Install the front planet carrier.
- Install the ring gear circlip.
- Install the planet carrier thrust bearing.
- Install the electric shift cam assembly.
- Install the reduction hub.
- Install the output shaft.
- Install the shift fork.
- Install the shift rail.
- Install the oil pump assembly.
- Install the magnet into its slot in the case.
- Install the thrust bearing assembly.
- Install the thrust washer.
- Install the thrust bearing.
- Install the thrust washer.
- Install the output shaft sprocket spacer.
- Install the drive chain and the sprockets as an assembly.
- Install the clutch pack spacer.
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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.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.