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, 13-56
   
   
   
   
   
   

   Item	Part Number	Description
   1	7045	Shaft Nut
   2	7B368	Output Shaft Yoke Washer
   3	7052	Oil Seal
   4	7B215	Yoke to Flange Seal
   5	—	Extension (Rear Spline) Cap, Bearing (Rear Yoke/Flange) (Serviced As Part of 7085 Assembly)
   6	7085	Extension Assembly (Rear Spline) Cap Assembly, Bearing (Rear Yoke/Flange)
   7	7A443	Bolt and Washer Assembly (1989 and Later)
   8	—	Flange (Rear Flange) (Serviced As Part of 7B214 Assembly)
   9	7917	Ring, Snap
   10	7025	Bearing
   11	7917	Ring, Snap
   12	7100	Shift Collar Hub
   13	7127	Caged Needle Bearing
   14	7A010	Plug, Pipe
   15	7917	Ring, Retaining
   16	7D164	Lockup Hub
   17	7D126	Spring, Lockup
   18	7106	Lockup Collar
   19	7177	Sprocket, Drive
   20	7A210	Hose
   21	382486-S	Clamp, Hose
   22	7A291	Transfer Housing to Case Bolt
   23	7E215	Retainer, Pump
   24	7A152	Cover, Pump
   25	7A149	Housing, Pump
   26	7A250	Pin, Pump
   27	7A205	Spring, Pump Pin
   28	7061	Output Shaft
   29	7100	Shift Collar Hub
   30	7A398	Front Planet
   31	7C122	Ring, Retaining
   32	7A153	Ring Gear
   33	7A098	Filter, Oil
   34	—	Gear, PTO (with PTO Only)
   35	7917	Ring, Retaining
   36	—	Ring, Retaining (Part of 7B215)
   37	7166	Case Deflector Gasket (with PTO Only)
   38	7165	Transfer Case Cover (with PTO Only)
   39	381673-S	Bolt (with PTO Only)
   40	7034	Vent
   41	7E440	4WD Indicator Switch
   42	—	Setscrew (Part of 7E440)
   43	—	Fork, Reduction (Serviced As Part of 7289 Assembly)
   44	—	Facing, Shift Fork (Serviced As Part of 7289 Assembly)
   45	7289	Ford Assembly Reduction
   46	7235	Roller, Cam (Service As Part of 7289 Assembly)
   47	—	Pin (Part of 7289)
   48	7C430	Facing, Shift Fork
   49	—	Retainer (Serviced As Part of 7289 Assembly)
   50	7289	Fork Assembly, Shift, 2W-4W
   51	7240	Shift Rail
   52	7219	Shift Fork Spring
   53	7C349	Spring, Detent
   54	7C191	Bushing, Detent
   55	7F063	Cam, Shift
   56	7288	Shifter Shaft Seal
   57	7B106	Lever, Shaft and Pin Assembly
   58	7005	Case
   59	—	Pin Dowel (Part of 7005)
   60	7L027	Oil Pan Magnet
   61	7917	Ring, Retaining
   62	7061	Output Shaft
   63	7177	Sprocket, Driven
   64	7119	Thrust Washer
   65	7917	Ring, Retaining
   66	7A029	Chain, Drive
   67	—	Yoke (Serviced As Part of 7B214 Assembly)

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

   
   
   
   
   

3. Remove the 4WD indicator switch and aluminum spacer washer from the transfer case. Do not lose this washer as it is required for the proper operation of this switch.

   
   
   
   
   

4. Remove the front and rear output shaft yoke to flange seals (7B215) using a screwdriver.

5. Remove the input shaft yoke to flange seal using screwdriver.

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

   Remove the four No. 50 Torx® head bolts (7A443) securing the rear bearing retainer to the case. Pry the rear bearing retainer from the rear case using a 1/2-inch drive breaker bar between the pry bosses and separate and remove the rear bearing retainer from the case. Remove all traces of silicone rubber from the mating surfaces of the case and the bearing retainer.

   
   
   
   
   

7. Remove the snap ring on the rear output shaft retaining the upper rear bearing (7025) using snap ring pliers.

8.  CAUTION: When removing the silicone rubber, use care not to damage the mating surfaces of the magnesium cases.

   Remove the 12 No. 50 Torx® head bolts that retain the front case to the rear case. Insert a 1/2-inch drive breaker bar between the pry bosses and separate. Lift the front case from the rear case. Remove all traces of RTV Gasket Sealant from the mating surfaces of the front case and the rear case.

   
   
   
   
   

9. Remove front output shaft caged needle bearing from the rear case with Impact Slide Hammer T50T-100-A and Collet D80L-100-T from Blind Hole Puller Set D80L-100-A or equivalent.

   
   
   
   
   

10. Drive out the rear output shaft bearing from the inside of the rear case using a brass drift, tapping it lightly with a small hammer so as not to cause any damage to the case.

    
    
    
    
    

11. Remove the snap ring from the output shaft securing the shift collar hub. Slide the shift collar hub off of the output shaft.

    
    
    
    
    
    

    Item	Part Number	Description
    1	7177	Drive Sprocket
    2	7106	Lockup Collar
    3	7100	Shift Collar Hub
    4	7917	Snap Ring
    5	—	Snap Ring Pliers
    6	7061	Output Shaft
    7	7219	Shift Fork Spring
    8	7177	Driven Sprocket
    9	7335	Mode Shift Fork

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

    
    
    
    
    

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

    
    
    
    
    

14. Remove the snap ring retaining the driven sprocket to the front output shaft. Grasp the drive and driven sprocket complete with the chain and lift them at the same time from the drive and driven output shafts.

    
    
    
    
    

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

16.  CAUTION: Do not disassemble oil pump unless the oil pump retaining bracket has been bent or broken, or pump damage is indicated. Indications of pump damage are blueing or blackening of the pump, or loosening of the pump bolts.

    Lift out the pump screen and remove the output shaft with the pump assembled on it. If the pump is to be disassembled, remove the four bolts from the pump body. Note the position of the pump front body, pins, spring, rear cover and pump retainer as removed.

    
    
    
    
    
    

    Item	Part Number	Description
    1	7E215	Oil Pump Retaining Bracket
    2	7061	Output Shaft Rear
    3	7A149	Oil Pump
    4	7289	High-Low Shift Fork
    5	7100	Hub Shift Collar

17. Remove the oil pan magnet (7L027) from its slot in the case.

18. 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.

    
    
    
    
    

19. Remove the shift collar hub.

20. Turn the front case over and remove the front input yoke to flange seal from the case using a screwdriver.

21. Reaching through the front opening with a pair of snap ring pliers, carefully expand the snap ring on the input shaft allowing it to drop out of the bearing. The front planet (7A398), including the input shaft, is serviced as an assembly only. If the bearing or bushing is to be replaced, drive out both of them through the input spline using suitable tools such as a brass drift and a small hammer, being careful not to damage the case.

    
    
    
    
    

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

    
    
    
    
    

23. Remove the internal snap ring securing the input shaft bearing to the case.

    
    
    
    
    

24. Remove the input shaft bearing using Bearing Cup Replacer T73T-1202-A and Driver Handle T80T-4000-W.

    
    
    
    
    

25. Remove the internal snap ring securing the front output shaft bearing in the case.

    
    
    
    
    

26. Drive the bearing out from the front of the case using Bearing Cup Replacer T73T-1202-B and Driver Handle T80T-4000-W.

    
    
    
    
    

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

28. Remove the setscrew using a hex key tool.

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

30. Remove the shift cam.

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

32. Remove the shift cam, assist spring, and assist spring 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

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.

Item	Part Number	Description
1	7A398	Front Planet and Input Shaft
2	7A153	Ring Gear
3	7100	Shift Collar
4	7177	Sprocket, Drive
5	7289	2W/4W Shift Fork
6	7061	Output Shaft (Rear)
7	7A149	Oil Pump
8	7240	Shift Rail
9	7289	High/Low Shift Fork
10	—	PTO Gear (Part of 7A398)

1. Install the input shaft and the front output shaft bearing in the case using Bearing Cup Replacer T80T-4000-P and Driver Handle T80T-4000-W. Install the internal snap rings retaining the bearing in the case.

   
   
   
   
   
   
   
   
   

2. Drive the front output yoke to flange seal into the case until it is fully seated against the case using Output Shaft Seal Replacer T86T-7034-CH.

   
   
   
   
   

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 shaft nut to 203-244 Nm (150-180 lb-ft).

4. Press the needle bearing and bronze bushing into the input shaft and carrier assembly with the appropriate tools, making sure that the bearing and bushing are 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. 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. While supporting the front planet in position, install a new snap ring on the front side of the input shaft bearing, making sure that it is fully seated in the snap ring groove of the input shaft.

8. Install the upper input shaft yoke to flange seal into the case using an appropriate tool until it is fully seated against the case.

   
   
   
   
   

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

10. Install the shift cam detent spring in position in the bushing of the shift cam and in the recess in the case.

11. 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.

12. Lubricate all pump parts with clean automatic transmission fluid prior to assembly.

13. Assemble the pump and output shaft as follows:

    1. Place the oil pump cover with the word TOP facing the front of the case.
    2. Install the two pins (with the flats facing toward the rear of the vehicle) with the spring between the pins and place the assembly in the oil pump bore in the output shaft.
    3. Place the oil pump body and pick-up tube over the output shaft and make sure that the pins are riding against the inside of the pump body.

    4. NOTE: The word TOP on the front cover and the rear cover should be on the same side.

       Place the oil pump rear cover with the words TOP REAR facing the rear of the output shaft.
    5. Install the pump retainer with the tabs facing the front of the transfer case.

    6. NOTE: The output shaft must turn freely within the oil pump. If binding occurs, loosen the four bolts and retighten as outlined.

       Install the four retaining bolts and rotate the output shaft while tightening the bolts to prevent the pump from binding. Tighten bolts to 4-4.5 Nm (36-40 lb-in).
       
       Rear Output Shaft and Oil Pump Installation
       
       
       
       
       
       

       Item	Part Number	Description
       1	7E215	Pump Retainer
       2	7A152	Oil Pump Front Cover
       3	7A149	Oil Pump Body and Pickup Tube
       4	7061	Output Shaft
       5	7A152	Oil Pump Rear Cover
       6	7A291	Retaining Bolts

14. 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.

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

16. 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 pump retainer and oil filter leg are in the groove and notch of the front case. Install the oil pan magnet in the slot in the front case.

    
    
    
    
    
    

    Item	Part Number	Description
    1	7061	Output Shaft Rear
    2	7A149	Oil Pump
    3	7061	Output Shaft Front
    4	7005	Case Front
    5	7240	Shift Rail

    
    
    
    
    
    

    Item	Part Number	Description
    1	7E215	Oil Pump Retainer
    2	7240	Shift Rail
    3	7289	High-Low Shift Fork
    4	7100	Shift Collar Hub
    5	7A149	Oil Pump

17. Assemble the following components:

    1. Assemble the drive sprocket into the chain.

    2. NOTE: The sprocket engagement spline will face the rear of the vehicle when properly installed.

       Assemble the driven sprocket into the chain so the word REAR is facing upward.
    3. Place the sprockets and chain as an assembly over the rear and front output shafts.
    4. Install the thrust washer (7119) and snap ring that retains the lower sprocket to the front output shaft.

18. Assemble the 2W-4W lockup as follows:

    1. Position the small end of the tapered compression spring in the lockup collar.

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

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

19. Install the lockup and its shift fork over the external splines of the drive sprocket and the shift rail with the cam follower feature of the fork facing the front of the transfer case.

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

21. Place the lockup hub over the external splines of the output shaft and secure with the appropriate snap ring. Make sure the snap ring is fully seated in the snap ring groove.

    
    
    
    
    
    

    Item	Part Number	Description
    1	7177	Drive Sprocket
    2	7106	2W-4W Lockup
    3	7100	Lockup Hub
    4	7917	Snap Ring
    5	—	Snap Ring Pliers
    6	7061	Output Shaft Rear
    7	7219	Shift Fork Spring
    8	7177	Driven Sprocket
    9	7335	Mode Shift Fork

22. Press the front output needle bearing in its bore in the rear case using an appropriate tool.

23. Press the rear output shaft bearing into position in the rear case using an appropriate tool. Install bearing snap ring retainer in rear case.

    
    
    
    
    

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

25.  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.

26. Place the case halves together making sure that the front output shaft, shift shaft and shift rail are aligned. Install and tighten the 12 No. 50-Torx® head bolts to 35-43 Nm (26-32 lb-ft).

27. Install the rear bearing snap ring on the output shaft making sure that the snap ring is fully seated in the groove of the output shaft.

    
    
    
    
    
    

    Item	Part Number	Description
    1	7061	Output Shaft Rear
    2	7025	Rear Bearing
    3	7005	Case
    4	7917	Snap Ring

28. Apply a very small bead of Black Non-Acid Cure Silicone Rubber ET7Z-19562-A or equivalent meeting Ford specification ESL-M4G273-A to the face of the rear bearing retainer or rear slip-yoke extension housing (7A039).

29. Place the rear bearing retainer or rear slip-yoke extension housing in its position and secure with the four Torx® bolts tightened to 30-49 Nm (22-36 lb-ft).

30. On transfer case with slip-yoke rear bearing retainer housing, remove the yoke to flange seal using a screwdriver. If the bushing in the rear slip yoke extension housing is damaged and must be replaced, it must be replaced with the extension housing as an assembly. The bushing alone cannot be serviced. Install a new seal using Extension Housing Seal Replacer T61L-7657-B.

31. For fixed yoke models, 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 163-203 Nm (120-150 lb-ft).

    
    
    
    
    

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

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

34. Install the transfer case.

35. Fill transfer case.

36. 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.