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: Electronic Shift Transfer Case: Assembly
- Remove the contamination and deposits from the transfer case housing and cover using a plastic scraper. Clean the transfer case housing and cover using a soft bristle brush to remove the contamination. Clean any remaining lip seal coating that may still be present on the housing or cover bores with a wire brush. Make sure the vent fitting and housing pockets are clean and clear. Use the General Equipment: Spatula
- Clean the transfer case housing and cover flange sealing surfaces. Refer to: RTV Sealing Surface Cleaning and Preparation
.
- Using the special tools, install the shift shaft seal.
Use Special Service Tool: 307-549 Installer, Shift Shaft Fluid 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 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 seal.
Use Special Service Tool: 308-250 (T96T-7127-B) Installer, Output Shaft Oil Seal.
- Using the special tool, install the input shaft seal.
Use Special Service Tool: 308-250 (T96T-7127-B) Installer, Output Shaft Oil Seal.
- Install the front output shaft.
- Install the front output shaft dust cover.
- 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 sprocket thrust washer.
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NOTE: Install the drive chain and sprockets as an assembly.
Install the drive chain and sprockets.
- Install the lock up hub, shift fork and shift fork spring.
- Install the field coil housing.
- Install the field coil housing snap ring.
- Install the transfer case field coil.
- If dowel pin is damaged install new dowel pin.
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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® Ultra Silicone Sealant / TA-29 (WSS-M4G323-A8)
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NOTE: Position the field coil bolts to align with the field coil bolt holes in the rear case. Position field coil wire through the field coil wire through hole in the case.
Position the transfer case halves and tighten the bolts in the sequence shown in illustration.
Torque
: 18 lb.ft (24 Nm)
- Install the transfer case field coil washers and the nuts.
Torque
: 89 lb.in (10 Nm)
- Clean the transfer case shift motor mating surface.
- Apply a small bead of silicone sealant to the transfer case shift motor mating surface.
Material
: Motorcraft® Ultra Silicone Sealant / TA-29 (WSS-M4G323-A8)
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NOTE: When installing the shift motor, tighten the bracket nuts last. Failure to follow the steps in the correct order may result in damage to the component.
- Install the transfer case shift motor.
- Install the transfer case shift motor bolts.
Torque
: 89 lb.in (10 Nm)
- Install the transfer case shift motor bracket bolt.
Torque
: 89 lb.in (10 Nm)
- Tighten the transfer case shift motor bracket nuts.
Torque
: 27 lb.in (3 Nm)
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NOTE: After the coil wire is inserted into the connector, gently pull the wire back to verify the pin is locked inside the connector.
Install the coil wire pin in the electrical connector.
- Insert the coil wire pin in the electrical connector.
- Install the inner connector retainer.
- Using the special tool, install the rear output shaft seal.
Use Special Service Tool: 308-249 (T96T-7127-A) Installer, Input Shaft Oil Seal.
- Install the vibration damper to the transfer case.
Torque
: 177 lb.in (20 Nm)
- 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.
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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.