Transfer Case - 1-Speed Torque-On-Demand: Assembly

WARNING: This page is about a different car, the 2017 Lincoln Navigator and 2017 Ford Expedition. However, it is still accessible from the selected car via links, so may be relevant.

1.

Lubricate all internal components with the recommended transfer case lubricant during reassembly.

2.

Clean the mating surfaces of the cases.

3.

Using a press and the Output Shaft Front Bearing Installer with the Handle, install the front input shaft bearing.

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4.

Using a press and the Front Axle Oil Seal Installer with the Handle, install the front shaft support bearing.

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5.

Using the Input Shaft Oil Seal Installer, install a new front output shaft seal.

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6.

Install the case to the Transmission Holding Fixture. Secure the case and the Transmission Holding Fixture to the work bench.

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7.

Using the Input Shaft Oil Seal Installer, install a new front input shaft seal.

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8.

Install the front output shaft and the snap ring.

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9.

Install the input shaft.

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10.

Install the output shaft.

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11.

NOTE: Make sure the oil pump finger is in the slot in the case.

Install the oil pump assembly.

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12.

Install the oil pan magnet into the slot in the case.

13.

Install the 3-piece thrust bearing assembly: the thrust washer, thrust bearing and thrust washer.

14.

Install the drive chain and the sprockets as an assembly.

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15.

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. Make sure to align the clutch pack with the sprocket.

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16.

Install a new snap ring.

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17.

Install the wave spring.

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18.

Install the cam and the steel balls.

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19.

Install the cam/coil housing.

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20.

Install the caged thrust bearing assembly.

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21.

Install the spacer.

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22.

Install the snap ring.

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23.

Using a press and the Mainshaft Bearing Installer, install the rear output shaft support bearing.

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24.

Using a press and the Mainshaft Bearing Installer, install the front output shaft rear bearing.

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25.

NOTE: Only apply enough silicone sealant to seal the transfer case halves together.

Apply a bead of silicone sealant to the transfer case mating surface. Position the 2 transfer case halves together, aligning the coil studs through the case holes. Tighten the 20 transfer case bolts evenly in a star pattern.
- Tighten to 29 Nm (21 lb-ft).

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26.

Install the 3 coil washers and nuts.
- Tighten to 10 Nm (89 lb-in).

27.

Using the Input Shaft Oil Seal Installer, install the rear output shaft seal.

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28.

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.

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29.

Install the connector bracket and the 2 connector bracket bolts.
- Tighten to 10 Nm (89 lb-in).

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30.

Install the transfer case dampener and the transfer case dampener bolts.
- Tighten to 18 Nm (159 lb-ft).

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31.

Secure the transfer case to a transmission jack and remove the transfer case from the Transmission Holding Fixture.

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