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Home >> Lincoln >> 2003 >> Navigator 4WD >> Repair and Diagnosis >> Transmission >> Transfer Case - Automatic Shift >> Disassembly And Assembly >> Transfer Case >> Assembly

Transfer Case: Assembly

  1. Lubricate all internal components with the recommended transfer case lubricant during reassembly.
  2. Clean the mating surfaces of the cases.
  3. Using a suitable press and the special tools, install the front planet support bearing.
    Fig 1: Installing Front Planet Support Bearing
    G01565412Courtesy of FORD MOTOR CO.
  4. Using a suitable press and the special tools, install the front output shaft support bearing.
    Fig 2: Installing Front Output Shaft Support Bearing
    G01565413Courtesy of FORD MOTOR CO.
  5. Using the special tool, install a new oil seal.
    Fig 3: Installing Oil Seal
    G01565414Courtesy of FORD MOTOR CO.
    6. CAUTION: Be careful not to crush the seal.
    Fig 4: Installing Shifter Shaft Seal
    G01565415Courtesy of FORD MOTOR CO.
  6. Using the special tool, install a new shifter shaft seal.
  7. Install the case to the transmission holding fixture. Secure the case to the work bench.
  8. Using the special tools, install a new oil seal.
    Fig 5: Installing Oil Seal
    G01565416Courtesy of FORD MOTOR CO.
  9. Install the ring gear.
    1. Position the ring gear in the case.
    2. Install the snap ring.
      Fig 6: Installing Ring Gear
      G01565417Courtesy of FORD MOTOR CO.
  10. Install the front output shaft and the snap ring.
    Fig 7: Installing Front Output Shaft And Snap Ring
    G01565418Courtesy of FORD MOTOR CO.
    11. NOTE: If removed, using a suitable press and the special tool 308-085, install the needle bearing into the front planet. Be careful not to crush the bearing cage.
    Fig 8: Installing Front Planet
    G01565419Courtesy of FORD MOTOR CO.
  11. Install the front planet.
  12. Install the shift fork shaft.
    Fig 9: Installing Shift Fork Shaft
    G01565420Courtesy of FORD MOTOR CO.
    13. NOTE: Assemble the reduction hub and the reduction shift fork.
    Fig 10: Installing Reduction Shift Fork, Reduction Hub, And Shift Cam
    G01565421Courtesy of FORD MOTOR CO.
  13. Install the reduction shift fork, the reduction hub, and the shift cam as an assembly.
  14. Install the output shaft.
    Fig 11: Installing Output Shaft
    G01565422Courtesy of FORD MOTOR CO.
  15. Install the oil pump assembly.
    • Make sure the oil pump finger is in the slot in the case.
      Fig 12: Installing Oil Pump Assembly
      G01565423Courtesy of FORD MOTOR CO.
  16. Install the oil pan magnet into its slot in the case.
    Fig 13: Installing Oil Pan Magnet
    G01565424Courtesy of FORD MOTOR CO.
  17. Install the output shaft hub.
    Fig 14: Installing Output Shaft Hub
    G01565425Courtesy of FORD MOTOR CO.
    18. NOTE: Assemble the lockup collar and the lockup fork.
    Fig 15: Installing Lockup Collar And Lockup Fork
    G01565426Courtesy of FORD MOTOR CO.
  18. Install the lockup collar and the lockup fork as an assembly.
  19. Install the three-piece thrust bearing assembly.
    1. Install the thrust washer.
    2. Install the thrust bearing.
    3. Install the thrust washer.
      Fig 16: Installing Thrust Bearing Assembly
      G01565427Courtesy of FORD MOTOR CO.
  20. Install the drive chain and the sprockets as an assembly.
    Fig 17: Installing Drive Chain And Sprockets
    G01565428Courtesy of FORD MOTOR CO.
    21. CAUTION: 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 can occur.
    Fig 18: Installing Clutch Pack Assembly
    G01565429Courtesy of FORD MOTOR CO.
  21. Install the clutch pack assembly.
  22. Install the lockup shift fork spring.
    Fig 19: Installing Lockup Shift Fork Spring
    G01565430Courtesy of FORD MOTOR CO.
  23. Install a new snap ring.
    Fig 20: Installing Snap Ring
    G01565431Courtesy of FORD MOTOR CO.
  24. Install the wave spring.
    Fig 21: Installing Wave Spring
    G01565432Courtesy of FORD MOTOR CO.
  25. Install the cam and the steel balls.
    Fig 22: Installing Cam And Steel Balls
    G01565433Courtesy of FORD MOTOR CO.
  26. Install the cam/coil housing.
    Fig 23: Installing Cam/Coil Housing
    G01565434Courtesy of FORD MOTOR CO.
  27. Install the thrust bearing assembly.
    Fig 24: Installing Thrust Bearing Assembly
    G01565435Courtesy of FORD MOTOR CO.
  28. Install the snap ring.
    Fig 25: Installing Snap Ring
    G01565436Courtesy of FORD MOTOR CO.
  29. Using a suitable press and the special tool, install the rear output shaft support bearing.
    Fig 26: Rear Output Shaft Support Bearing
    G01565437Courtesy of FORD MOTOR CO.
  30. Using a suitable press and the special tool, install the front output shaft rear bearing.
    Fig 27: Installing Front Output Shaft Rear Bearing
    G01565438Courtesy of FORD MOTOR CO.
    31. CAUTION: Applying too much silicone sealant can plug the fluid filter and cause transfer case failure.
  31. Apply a bead of silicone sealant to the transfer case mating surfaces, then position the two transfer case halves together. Tighten the bolts evenly in a star pattern.
    • Position the coil studs through the case holes, make sure the shift cam shaft is aligned with its case bore, and the lockup shift fork spring is in position.
      Fig 28: Positioning Transfer Case Halves Together
      G01565439Courtesy of FORD MOTOR CO.
      Fig 29: Tightening Transfer Case Bolts
      G01565440Courtesy of FORD MOTOR CO.
  32. Install the coil washers and nuts.
    Fig 30: Icoil Washers And Nuts
    G01565441Courtesy of FORD MOTOR CO.
  33. Using the special tool, install the oil seal.
    Fig 31: Installing Oil Seal
    G01565442Courtesy of FORD MOTOR CO.
  34. Install the transfer case shift motor.
    Fig 32: Installing Transfer Case Shift Motor
    G01565443Courtesy of FORD MOTOR CO.
  35. Install the coil wire pin in the electrical connector.
    1. Remove the wire connector spacer.
    2. Install the coil wire pin. Reinstall the wire connector spacer.
      Fig 33: Installing Coil Wire Pin
      G01565444Courtesy of FORD MOTOR CO.
  36. Remove the transfer case from the special tool.
    Fig 34: Removing Transfer Case From Special Tool
    G01565445Courtesy of FORD MOTOR CO.
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