Transfer Case - Automatic Shift: Removal & Installation Ford Ranger I

Installation

1. Follow the removal procedure in reverse order.

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Scheme 108

1. Remove the transfer case from the vehicle. For additional information, refer to «TRANSFER CASE»(ref-204989-S31606951042005111600000) .
2. Attach the transfer case to the special tool.
3. Use the special tool to prevent the flange from turning. Remove and discard the nut and the washer.
4. Using a suitable puller, remove the flange.
5. Remove the oil seal if it remains on the rear output shaft.
6. Using the special tool, remove the oil seal.
7. Remove the spacer.
8. Remove the bolts retaining the harness to the motor assembly and connector.
9. Remove the rear bolt.
10. Remove the front bolt and the motor assembly and connector.
11. Remove the bolts that retain the transfer case cover to the transfer case.
12. Remove the bolts that retain the transfer case to the transfer case cover.
13. Insert a breaker bar between the pry bosses, and separate the transfer case cover from the transfer case.
14. Remove the snap ring that retains the bearing in the case.
15. Using the special tools, remove the bearing.
16. Using the special tools, remove the needle bearing.
17. Remove the following: Remove the shift collar hub. Remove the return spring. Remove the lockup collar and the lockup fork as an assembly. Remove the electric shift cam assembly. Remove the shift rail.
18. Remove the snap ring.
19. Remove the lockup hub and the sleeve return spring from the lockup collar.
20. Remove the snap ring and the spacer.
21. Remove the drive chain, the driven sprocket, and the drive sprocket as an assembly.
22. Remove the magnet and the oil strainer from the slot in the transfer case.
23. Remove the rear output shaft and the pump assembly as an assembly.
24. Rotate the pump assembly to align the keyway in the cover and the spring pin in the rear output shaft, and separate the pump from the shaft.
25. Using a micrometer, measure and record the pump drive pin height above the diameter of the rear output shaft, and remove the drive pin from the rear output shaft.
26. Remove the snap ring. Discard the snap ring if deformed during removal.
27. Remove the front output shaft assembly.
28. Remove the reduction fork assembly and the reduction hub as an assembly.
29. Remove the six bolts retaining the front adapter assembly to the case.
30. Remove the front adapter assembly, the input shaft assembly, and the complete carrier assembly as an assembly.
31. Using snap ring pliers, expand the tangs of the large snap ring and remove the complete carrier assembly and the input shaft assembly from the front adapter.
32. Remove the large snap ring from the front adapter.
33. Using a suitable tool, remove the oil seal from the front adapter.
34. Remove the snap ring.
35. Using the special tool and a suitable press, remove the bearing.
36. Remove the thrust washer and the input shaft assembly.
37. Remove the snap ring, the thrust plate, and the sun gear.
38. Using the special tools and a suitable press, remove the needle bearing and the sleeve bearing from the input shaft.
39. Using a suitable tool, remove the oil seal.
40. Remove the snap ring retaining the bearing to the case.
41. Using the special tools, remove the bearing.
42. Using a suitable tool, remove the oil seal.
43. Remove the shift fork facings.
44. Remove the electric shift cam from the shift shaft.
45. Remove the torsion spring and the spacer from the shift shaft.