Assembly

Note: Prior to assembly, lubricate all parts with MERCON Multipurpose Automatic Transmission Fluid WSP-M2C185-A or MERCON equivalent.





1. Drive the bearing into the front output case bore, using the Output Shaft Seal Replacer and Drive Handle, and install the retaining internal snap ring.





2. Install the front yoke to flange seal, using the Output Shaft Seal Replacer and Drive Handle.





3. Note: Align the serrations on the outside of the ring gear to the serrations previously cut in the front case bore.

Using a press, install the ring gear.





4. Use the Output Shaft Seal Replacer and Drive Handle to install the input yoke to flange seal into the mounting adapter bore.





5. Use the Input Shaft Bearing Replacer to press a new needle bearing and bushing into the end of the input shaft.





6. Note: The recessed face of the overdrive sun gear and the snap ring groove on the bearing outer race must be toward the rear of the transfer case.

Note: The stepped face of the thrust washer must face toward the bearing.

Slide the overdrive sun gear, thrust plate and thrust washer into position on the input shaft.





7. Press the bearing over the input shaft.





8. Install the external snap ring to the input shaft.





9. Install the internal snap ring to the planetary carrier.





10. Place the tanged snap ring in the mounting adapter groove.





11. Place the input shaft and front planet in the main drive gear bearing retainer, and expand the tanged snap ring while pushing inward until the front planet and input shaft are seated in the main drive gear bearing retainer.
- Check the installation by holding the main drive gear bearing retainer by hand and carefully tapping the face of the input shaft against a wooden block to make sure the snap ring is engaged.





12. CAUTION: The main drive gear bearing retainer must be installed within 15 minutes of the application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has properly cured.

Install a bead of RTV Gasket Sealant on the surface of the front case.
- Use Non-Acid Cure Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M4G273-A.





13. Position the main drive gear bearing retainer on the front case, and tighten the six bolts.
14. Mount the transfer case front on the holding fixture.





15. Make sure the nylon wear pads are installed on the shift fork and snapped securely into place.





16. Install the high-low collar as an assembly into the front planet.





17. Note: If a measurement was not taken during the disassembly, install the pin to a height of 1.0 mm (0.40 inch).

Press the pin into the rear output shaft pinhole to the previously measured height.





18. Note: Do not remove the plastic insert from the bore of a new pump. Discard it after it slides out during the pump installation to the rear output shaft.

Note: If a new pump is used, slide the pump housing slot onto the pin of the output shaft with the retaining arm of the cover toward the rear of the case.

Note: While turning the output shaft, prime the pump through the oil filter pickup tube or housing inlet hole with clean Motorcraft MERCON Multipurpose Automatic Transmission Fluid WSP-M2C185-A or MERCON equivalent.

Install the oil pump onto the rear of the output shaft.





19. If the oil pump does not turn freely after installation to the rear output shaft, realign the cover keyway to the pin of the rear output shaft and jiggle the pump until it fully seats and rotates freely.





20. Install the output shaft and oil pump in the input shaft.





21. Install the oil pan magnet in the slot in the front case just above the oil filter leg.





22. Install the front output shaft in the front case.





23. Install the front output shaft retaining snap ring.





24. Assemble the 2W-4W lockup assembly.
- Install the sleeve return spring into the bore of the lockup collar with the large end installed first.
- Place the lockup hub over the spring, and install the lockup hub into the lockup collar.





25. Press down and install the internal snap ring.





26. Note: The driven sprocket (on the front output shaft) must be installed with the marking REAR facing toward the rear case, if so marked.

Install the chain, drive sprocket and driven sprocket as an assembly over the output shaft.





27. Install the thrust washer and the external snap ring over the thrust washer to retain the driven sprocket.





28. If removed, slide the spring spacer on the camshaft and position it beneath the drive tang.





29. If removed, place the torsion spring on the camshaft, and position the first spring tang to the left of the camshaft drive tang.





30. Wind the second spring tang clockwise past the drive tang, and push the torsion spring and sleeve in as far as it will go.





31. Install the helical cam, and slide the drive tang between the torsion spring tangs as far as it will go.





32. CAUTION: Do not bend the helical cam during installation to the front case because of possible damage to the pin at the tang end of the motor shaft.

Install the pin on the tang end of the helical cam into the hole in the front case.





33. Position the torsion spring tangs so that they are pointing toward the top side of the transfer case and just touching the high-low shift fork.





34. Install the shift rail through the high-low shift fork, and make sure that the shift rail is seated in the front case bore.





35. Install the 2W-4W shift fork to the 2W-4W lockup, and install the lockup and shift fork over the output shaft and onto the shift rail.





36. Note: After the 2W-4W shift fork is released, make sure the 2W-4W fork roller bushing is resting on the top surface of the helical cam and not into an inside track.

The triangular shaft will be in the two-wheel high (2H) position at final assembly.





37. Lift the 2W-4W shift fork slightly while holding the shift rail down, and rotate the helical cam track into the high-low fork roller bushing by turning the helical cam.





38. Install the clutch housing on the output shaft with the cavity side or notches facing the rear case.





39. Drive the front output shaft needle bearing into the rear cover bore with the Front Shaft Needle Bearing Replacer and Drive Handle.





40. Install the rear output bearing in the rear case bore, using the Output Shaft Bearing Replacer and Drive Handle, and install the internal snap ring that retains the bearing to the rear case.





41. CAUTION: Do not kink or trap the wire while seating the clutch coil to the case.

CAUTION: The clutch coil must be installed within 15 minutes of the application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has properly cured.

Apply a small bead of Non-Acid Cure Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M4C1273-A to the base of the clutch coil studs and grommet, and install the clutch coil from inside the rear case.





42. Tighten the clutch coil nuts.





43. Install the lockup return spring to the shift rail and shift fork with the spring mounted in a vertical position.





44. Install the rear output yoke to flange seal, using the Drive Handle and the Seal Installer.

45. CAUTION: The cases must be assembled within 15 minutes of the application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has properly cured.

Coat the mating surface of the front case with a bead of Non-Acid Cure Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M4G273-A.





46. Assemble the cases.
- Align the output shaft with the rear case output shaft bore.
- Align the helical cam with the rear case motor bore.
- Align the rear case so that the spring boss engages the lockup return spring and shift rail.





47. Install the front bolts retaining the case halves and tighten.





48. Install the rear bolts.





49. Note: If the shaft will not stay in the 4H position, rotate the shaft clockwise to the 2H position. During motor installation, rotate the transfer case shift motor counterclockwise until the transfer case shift motor is aligned with the mounting holes.

50. Install the transfer case shift motor.





51. Install the spacer into the rear case bore.





52. Install the rear output flange, washer and nut.
53. Fill the transfer case with 1.2 liters (2.5 pints) of Motorcraft MERCON Multipurpose Automatic Transmission Fluid WSP-M2C185-A or MERCON equivalent.





54. Install the fill plug.
55. Install the transfer case.