July 1: So it begins. Don't worry, this is not in the correct legal jurisdiction!

Transfer Case - Expedition: Assembly

WARNING: This page is about a different variant/trim than selected.

Lubricate all internal components with the recommended transfer case lubricant during reassembly.
Clean the mating surfaces of the cases.
Using a suitable press and the Output Shaft Front Bearing Installer with the Handle, install the front planet support bearing.

Fig 1: Installing Front Planet Support Bearing
Courtesy of FORD MOTOR CO.
Using a suitable press and the Front Axle Oil Seal Installer with the Handle, install the front output shaft support bearing.

Fig 2: Installing Front Output Shaft Support Bearing
Courtesy of FORD MOTOR CO.
Using the Input Shaft Oil Seal Installer, install a new front output shaft seal.

Fig 3: Installing Front Output Shaft Seal
Courtesy of FORD MOTOR CO.
Using the Valve Stem Oil Seal Installer, install a new shift shaft seal.

Fig 4: Installing Shift Shaft Seal
Courtesy of FORD MOTOR CO.
Install the case to the Transmission Holding Fixture. Secure the case and the Transmission Holding Fixture to the work bench.

Fig 5: Installing Case To Transmission Holding Fixture
Courtesy of FORD MOTOR CO.
Using Input Shaft Oil Seal Installer, install a new front input shaft seal.

Fig 6: Installing Front Input Shaft Seal
Courtesy of FORD MOTOR CO.
Install the ring gear.
1. Position the ring gear in the case.
2. Install the snap ring.
Fig 7: Locating Ring Gear And Snap Ring
Courtesy of FORD MOTOR CO.
Install the front output shaft and the snap ring.
NOTE: If removed, using a suitable press and the Input Shaft Bearing Installer, install the needle bearing into the front planet. Be careful not to damage the bearing cage.

Install the front planet.

Fig 8: Locating Front Planet
Courtesy of FORD MOTOR CO.
Install the shift fork shaft.

Fig 9: Locating Shift Fork Shaft
Courtesy of FORD MOTOR CO.
Assemble the reduction hub and the reduction shift fork. Install the reduction shift fork, the reduction hub and the shift cam as an assembly.

Fig 10: Locating Reduction Shift Fork, Reduction Hub And Shift Cam Assembly
Courtesy of FORD MOTOR CO.
Install the output shaft.

Fig 11: Locating Output Shaft
Courtesy of FORD MOTOR CO.
NOTE: Make sure the oil pump finger is in the slot in the case.

Install the oil pump assembly.

Fig 12: Locating Oil Pump Assembly
Courtesy of FORD MOTOR CO.
Install the oil pan magnet into the slot in the case.

Fig 13: Installing Oil Pan Magnet Into Slot In Case
Courtesy of FORD MOTOR CO.
Install the 3-piece thrust bearing assembly.
1. Install the thrust washer.
2. Install the thrust bearing.
3. Install the thrust washer.
Fig 14: View Of 3-Piece Thrust Bearing Assembly
Courtesy of FORD MOTOR CO.
Install the drive chain and the sprockets as an assembly.

Fig 15: Locating Drive Chain And Sprockets
Courtesy of FORD MOTOR CO.
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.

NOTE: If the clutch pack is disassembled, a new clutch pack must be installed and the armature transferred. Failure to install a new clutch pack can result in component failure.

Install the clutch pack assembly with the armature.

Fig 16: Locating Clutch Pack Assembly
Courtesy of FORD MOTOR CO.
Install a new snap ring.

Fig 17: Locating Snap Ring
Courtesy of FORD MOTOR CO.
Install the wave spring.
Install the cam and the steel balls.

Fig 18: Locating Steel Balls And Cam
Courtesy of FORD MOTOR CO.
Install the cam/coil housing.

Fig 19: Locating Cam/Coil Housing
Courtesy of FORD MOTOR CO.
Install the thrust bearing assembly.
Install the snap ring.
Using a suitable press and the Mainshaft Bearing Installer, install the rear output shaft support bearing.

Fig 20: Installing Rear Output Shaft Support Bearing
Courtesy of FORD MOTOR CO.
Using a suitable press and the Mainshaft Bearing Installer, install the front output shaft rear bearing.

Fig 21: Installing Front Output Shaft Rear Bearing
Courtesy of FORD MOTOR CO.
NOTE: Applying too much silicone sealant will plug the fluid filter and cause transfer case failure.

Apply a bead of silicone sealant to the transfer case mating surface, then position the 2 transfer case halves together. Tighten the 20 transfer case bolts evenly in a star pattern.
- Position the coil studs through the case holes, making sure the shift cam shaft is aligned with its case bore and the lockup shift fork spring is in position.
- Tighten to 29 Nm (21 lb-ft).
Fig 22: Locating Transfer Case Bolts
Courtesy of FORD MOTOR CO.
Install the 3 coil washers and nuts.
- Tighten to 10 Nm (89 lb-in).
Using the Input Shaft Oil Seal Installer, install the rear output shaft seal.

Fig 23: Installing Rear Output Shaft Seal
Courtesy of FORD MOTOR CO.
Apply a small bead of silicone sealant to the transfer case shift motor mating surface.
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 and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
Install the transfer case shift motor bracket bolt.
- Tighten to 10 Nm (89 lb-in).
Secure the transfer case shift motor bracket nuts.
NOTE: After the wire is inserted into the connector, gently pull the wire back to verify the pin is locked inside the connector.

Insert the coil wire pin in the electrical connector and install the inner connector retainer.

Fig 24: Locating Coil Wire Pin In Electrical Connector
Courtesy of FORD MOTOR CO.
Secure the transfer case to a suitable transmission jack and remove the transfer case from the Transmission Holding Fixture.

Fig 25: Removing Transfer Case From Transmission Holding Fixture

G07458760

Courtesy of FORD MOTOR CO.