Transfer Case - Automatic Shift: Overhaul Ford Ranger I

Assembly

Note. Prior to assembly, lubricate all parts with MERCON® Multi-Purpose (ATF) Transmission Fluid.

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1. Using the special tools and a suitable press, install the bearing.
2. Install the snap ring.
3. Using the special tool, install the oil seal.
4. Using the special tools and a suitable press, install the needle bearing.
5. Using the special tools and a suitable press, install the sleeve bearing.
6. Install the sun gear, the thrust plate, and the snap ring.
7. Install the input shaft assembly and the thrust washer.
8. Using a suitable press, install the bearing.
9. Install the snap ring.
10. Using the special tool, install the oil seal.
11. Install the large snap ring in the groove in the front adapter.
12. Apply a 3-mm (1/8-inch) bead of silicone sealant to the front adapter mounting surface of the transfer case.
13. Position the front adapter on the transfer case, and install the six bolts.
14. Install the input shaft assembly and the complete carrier assembly as an assembly. Align the pinion gears gear teeth and the ring gear teeth. Expand the snap ring and push inward on the planet carrier until the input shaft assembly seats fully in the front adapter. Verify that the snap ring engaged the assembly by holding the front adapter and lightly tapping the face of the input shaft assembly against a wooden block.
15. Attach the front case to the special tool.
16. Install the new shift fork facings. Verify that they snap securely into place.
17. Install the reduction hub and the reduction fork assembly as an assembly.
18. Press the pin into the rear output shaft pin hole to the previously measured height.
19. Install the pump assembly on the rear output shaft. Align the keyway in the cover and the spring pin in the rear output shaft and fully seat the pump assembly on the shaft. The shaft will rotate freely in the pump assembly when the pump assembly is fully seated.
20. If the pump assembly does not turn freely, realign the keyway and the spring pin and jiggle the pump assembly until it seats fully and rotates freely on the shaft.
21. Prime the pump assembly. Submerge the pump in a container full of clean MERCON® Multi-Purpose (ATF) Transmission Fluid.
22. Install the rear output shaft and the pump assembly.
23. Install the oil strainer and the magnet in the slot in the case.
24. Install the front output shaft assembly.
25. Install the snap ring.
26. Install the drive chain, the drive sprocket and the driven sprocket as an assembly.
27. Install the spacer and the snap ring.
28. Install the shift rail through the reduction shift fork. Verify that the shift rail seats in the case bore.
29. Slide the spacer and the torsion spring on the shift shaft and position it beneath the drive tang.
30. Position the first spring tang to the left of the drive tang.
31. Wind the second spring tang clockwise past the drive tang, and push the torsion spring and sleeve in as far as it will go.
32. Install the electric shift cam, and slide the drive tang between the torsion spring tangs as far as it will go.
33. Install the pin on the end of the shift shaft into the hole in the case.
34. Position the torsion spring tangs so that they point toward the top side of the case and just touch the reduction shift fork.
35. Assemble the lockup assembly.
36. Press downward on the lockup hub and install the snap ring.
37. Install the lockup fork and the lockup collar as an assembly.
38. The triangular shaft will be in the two-wheel high (2H) position at final assembly.
39. Lift upward on the lockup fork slightly while holding down on the shift rail and rotate the electric shift cam track into the cam roller by turning the shift shaft.
40. Install the shift collar hub and the return spring.
41. Using the special tools and a suitable press, install the needle bearing.
42. Using the special tools and a suitable press, install the bearing.
43. Install the snap ring that retains the bearing to the transfer case cover.
44. Using the special tool, install the oil seal.
45. Apply a 3-mm (1/8-in) bead of silicone sealant to the mating surface of the front case.
46. Assemble the cases. Align the output shaft, the shift shaft, and the return spring to their respective bores in the transfer case cover.
47. Install the bolts.
48. Install the bolts.
49. Install the spacer on the rear output shaft.
50. Using the special tool, install the oil seal.
51. Position the flange on the rear output shaft. If necessary, reseat the oil seal in the flange.
52. Install a new oil seal in the flange.
53. Using the special tool, install the flange. Tighten the nut on the special tool to 54 Nm (40 lb-ft) to seat the flange on the shaft.
54. Use the special tool to prevent the flange from turning. Install a new washer and a new nut.
55. If the shift shaft will not stay in the 4H position, rotate the shift shaft clockwise to the 2H position. During motor assembly and connector installation, rotate the motor assembly counterclockwise until the motor assembly aligns with the mounting holes.
56. Apply a thin coat of silicone sealant to the base of the motor housing.
57. Install the motor assembly and connector.
58. Install the transfer case. For additional information, refer to «TRANSFER CASE»(ref-204989-S31606951042005111600000) .

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1. With the vehicle in NEUTRAL, raise and support the vehicle.
2. Remove the skid plate.
3. Remove the damper, if so equipped.
4. Disconnect the transfer case harness connector and position it aside.
5. If transfer case (7005) disassembly is necessary, remove the drain plug and drain the fluid. Install the drain plug when all of the fluid has drained.
6. Disconnect the front driveshaft from the transfer case and position the driveshaft aside. Index-mark the front output shaft assembly and the front driveshaft Constant Velocity (CV) joint. Remove and discard the bolts and washers. Disconnect the front driveshaft from the transfer case and position the driveshaft aside.
7. Remove the rear driveshaft. For additional information, refer to «DRIVE SHAFTS»(ref-153359) .
8. Position a high lift jack under the transfer case.
9. Remove the transfer case from the vehicle. Remove the five bolts retaining the transfer case to the extension housing. Slide the transfer case rearward and off of the transmission output shaft. Remove and discard the front extension housing gasket (7086), and clean the mating surfaces.

1. To install, reverse the removal procedure.
2. Check and, if necessary, fill the transfer case with the specified type and quantity of fluid. For additional information, refer to «TRANSFER CASE DRAINING & FILLING»(ref-204989-S38483925202005111600000) .