Transfer Case, Mechanical Shift

Disassembly

1. Remove transfer case (7A195) from vehicle. Refer to Transfer Case procedure in the Removal and Installation portion of this section.

   Transfer Case, Manual Shift, 44-07

   

   Item	Part Number	Description
   1	7N430	Bearing
   2	7085	Bearing Retainer
   3	7100	Shift Collar Hub
   4	7917	Snap Ring
   5	7D164	Lockup Hub
   6	7D126	Lockup Spring
   7	7106	Lockup Collar
   8	7177	Drive Sprocket
   9	7A149	Oil Pump
   10	382486-S	Clamp, Hose
   11	7A210	Coupling Hose
   12	—	Gear (with PTO Only)
   13	7A398	Front Planet
   14	7Z111	Thrust Washer
   15	7061	Output Shaft
   16	7D221	Thrust Bearing
   17	7165	Transfer Case Cover (with PTO Only)
   18	7005	Case
   19	—	Pin Dowel (Part of 7005)
   20	7A153	Ring Gear
   21	7064	Snap Ring
   22	7A443	Bolt
   23	7B215	Yoke to Flange Seal
   24	7B214	Case Yoke
   25	7052	Oil Seal
   26	7B368	Output Shaft Yoke Washer
   27	7045	Shaft Nut
   28	7A010	Case Plug
   29	7219	Reverse Kick Down Spring
   30	7289	Fork, Shift, 2WD-4WD
   31	7F063	Shift Cam
   32	7L027	Oil Pan Magnet
   33	7A098	Pickup Tube
   34	7C191	Bushing, Detent
   35	7C349	Spring, Detent
   36	7240	Shift Rail
   37	—	Fork, Reduction (Part of 7289)
   38	7C430	Shift Fork Facing
   39	7A029	Drive Chain
   40	7177	Driven Sprocket
   41	7B106	Shaft and Pin Lever
   42	7288	Shifter Shaft Seal
   43	—	Setscrew (Part of 7E440)
   44	7E440	4WD Indicator Switch
   45	7034	Vent
   46	381673-S	Bolt (with PTO Only)
   47	7025	Bearing

2. Remove front output shaft nut (7045), output shaft yoke washers (7B368), and oil seal (7052) and remove the front output case yoke (7B214) from the transfer case. Repeat procedure for rear output circular case yoke.

   

3. Remove the 4WD indicator switch.

   

4. NOTE: Discard yoke to flange seal (7B215), after it is removed.

   Remove the rear output yoke to flange seal from the rear case with a screwdriver.

5.  CAUTION: When removing RTV sealant, use care not to damage the mating surfaces of the cases (7005).

   Remove the 20 No. 40 Torx® head bolts (7A443) that retain the front case to the rear case. Insert a 1/2-inch drive breaker bar between the pry bosses and separate. Pull the rear case from the front case.

   

   

6. Remove front output shaft bearing from the rear case using suitable bearing remover tool.

7. Slide the shift collar hub off the output shaft.

8. Remove the shift fork spring from the shift rail and lift the mode (2WD/4WD) shift fork complete with the lockup collar from the rear output shaft.

   

9. Disassemble the 2W-4W lockup assembly by removing the internal snap ring and pull the lockup hub and spring from the lockup collar.

   

10. Grasp the drive and driven sprocket complete with the chain and lift them at the same time from the drive and driven output shafts.

    

11. Remove the shift rail by sliding it straight out from the shift fork.

12. Remove the bearing support and bearing assembly.

13. Drive the bearing from the center using a brass drift and a light mallet to avoid damaging the bearing support.

    

14.  CAUTION: Do not attempt to disassemble or service the gerotor pump assembly. The pump should rotate freely on the shaft. If the pump binds on the shaft, it must be replaced.

    Lift out the pump screen and remove the output shaft with the pump assembled on it.

15. Remove the two oil pan magnets (7L027) from their slots in the case.

16. Remove the high-low shift fork by first rotating it until the roller is free from the cam, then sliding out of engagement from the shift collar hub.

    

17. Remove the shift collar hub.

18. Remove the thrust bearing from the front planet (7A398).

19. Remove the front planet. The front planet is serviced as an assembly only. The inside diameter of the bushing is 1.25 inches and the outside diameter is 1.5 inches. If the unit features a PTO gear, remove the PTO gear from the front planet.

    

20. Remove the ring gear (7A153) by prying out the internal snap ring with a screwdriver and lift out the gear.

    

21. NOTE: Discard yoke to flange seals after they are removed.

    Remove input shaft and front output shaft yoke to flange seals with a screwdriver.

22. Drive out the input shaft front output shaft bearings (7025) from the inside of the case using a brass drift, tapping them lightly with a small mallet so as not to cause any damage to the case.

    

23. Place the shift lever in the NEUTRAL position so the shift cam setscrew can be seen through the hole for the 4WD indicator switch.

24. Remove the setscrew using a hex key tool.

25. Remove the shift lever by sliding it out of the case.

26. Remove the shift cam.

27. Remove the shifter shaft seal (7288) by carefully prying it out of the case, being careful not to damage the case.

28. Remove the shift cam detent spring, and detent bushing from the case.

    

    Item	Part Number	Description
    1	7C349	Shaft Cam Detent Spring
    2	7B101	Shift Lever
    3	—	Setscrew Hole (Part of 7F063)
    4	7F063	Shift Cam
    5	—	Bushing (Part of 7C349)

Assembly

NOTE: Before assembly, lubricate all parts with Motorcraft MERCON® ATF XT- 2-QDX or MERCON® equivalent. Remove all chips from the bolt holes in the case and rear case. Remove all traces of RTV Gasket Sealant from the mating surfaces of the front case and the rear case.

1. Install the input shaft bearing and the front output shaft bearing in the case using a suitable tool.

2. Drive the input and front output yoke to flange seals into the case until they are fully seated against the case using suitable shaft seal installing tool.

   

   

3. Install the front output shaft through the lower bearing. The front output shaft is held in place in the case by the front output yoke to flange seal and oil seal slinger. Install the front case yoke onto the front output shaft, then the oil seal, output shaft yoke washer and 32mm shaft nut. Tighten the yoke lock nut to 203-244 Nm (150-180 lb-ft).

4. If removed, press the bronze wedding band bushing into the input shaft and carrier assembly with the appropriate tools, making sure bushing is driven in straight.

5. Install the ring gear into the slots in the case and retain it with the large internal snap rings making sure that it is fully seated.

6. NOTE: Take care when guiding the input shaft (7017) through the input yoke to flange seal, so as not to roll the lip of the yoke to flange seal inside out.

   Install the input shaft and front planet in the case through the input shaft bearing, being careful not to damage the gear teeth when aligning them with the ring gear teeth.

7. Install a new shifter shaft seal into the case using an appropriate tool.

8. Install the shift cam assist spring in position in the bushing of the shift cam and in the recess in the case.

9. Assemble the shift cam into the case by sliding the shift shaft and lever through the case and seal into engagement with the shift cam. Install the setscrew through the holes in the case for the 4WD indicator switch. Tighten to 8-12 Nm (71-108 lb-in).

10. Install thrust bearings and thrust washers in front planet.

    

11. Install the shift collar. Install the high-low shift fork by engaging it with the shift hub flange and rotating it until the roller is engaged with the lower groove of the cam.

12. Install the shift rail through the high-low fork bore and into the rail bore in the case.

13. Install the output shaft and oil pump in the input shaft. Make sure the external splines of the output shaft engage the internal splines of the shift collar hub. Make sure the oil filter leg is in the notch of the front case. Install the oil pan magnets in the slots in the front case.

14. Install center support bearing in bearing support using a suitable bearing replacer and Driver Handle T80T-4000-W.

15. Install bearing support with bearing in the front case. Make sure the bearing support properly engages with the case and that the pump anti-rotation tab is properly engaged with the bearing support.

16. Components should be assembled in the following sequence:

    1. Assemble the drive and driven sprockets in the drive chain outside the transfer case. The external splined boss on the drive sprocket and the plain extended boss on the driven sprocket should face upward.
    2. Place the sprockets and drive chain as an assembly over the front and rear output and fifth gear drive shafts (7061). The bosses on the sprockets should face the rear of the transfer case.

17. Assemble the 2W-4W lockup assembly as follows:

    1. Position the large end of the tapered compression lockup spring in the lockup hub.

    2. NOTE: The snap ring holds the lockup together.

       Place the lockup hub over the small end of the spring and compress the spring while installing the internal snap ring.

       

18. Install the lockup and its shift fork over the external splines of the drive sprocket and the shift rail so that the cam follower feature of the shift fork is against the shift cam.

19. Assemble the 4WD return spring over the shift rail and against the shift fork.

20. Place the lockup hub over the external splines of the output shaft.

    

    Item	Part Number	Description
    1	7106	2W-4W Lockup
    2	7100	Shift Collar Hub
    3	7219	Shift Fork Spring
    4	7177	Driven Sprocket
    5	7061	Output Shaft Rear
    6	7335	Mode Shift Fork
    7	7177	Drive Sprocket

21. Press the front output shaft bearing in its bore in the rear case using an appropriate tool.

22. Press the rear output shaft bearing into position in the case using an appropriate tool.

23. Install the rear output shaft yoke to flange seal in the rear case using the appropriate tool and making sure that it is fully seated.

24.  CAUTION: If too much silicone rubber is used when sealing the case halves, the excess sealant may plug the oil filter and cause case failure.

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

25. Place the case halves together making sure that the front output shaft, shift shaft and shift rail are aligned. Install and tighten the 20 No. 40-Torx® head bolts to 30-49 Nm (22-36 lb-ft).

26. Install the rear output shaft case yoke and slinger onto the rear splines of the output shaft. Install the oil seal, output shaft yoke washer and 32mm shaft nut on the output shaft and tighten to 203-244 Nm (150-180 lb-ft).

    

27. Install the drain plug and tighten to 9-23 Nm (7-17 lb-ft).

28. Install the 4WD indicator switch with aluminum washer into the case. Tighten 4WD indicator switch to 34-47 Nm (25-35 lb-ft).

29. Install the transfer case.

30. Fill transfer case.

31. Start engine, check transfer case for correct operation. Stop engine and check fluid level. Fluid should drip out of level hole. If fluid flows out of level hole, the oil pump may not be functioning properly.