Transfer Case - Mechanical 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, press a new bearing into the transfer case.
2. Install the snap ring.
3. Using the special tool, install the oil seal.
4. Install the shift mechanism into the case. Install the shift cam. Install the shift shaft. Install the clip. Install the detent. Install the four-wheel drive switch.
5. After the shift cam, shift shaft and C-clip have been installed in the front case and with the shift shaft positioned in the 4H detent position, place the spring roller into part-position on the 90 degree bent tang of the spring and insert the roller into the spring/roller slot of the shift cam. Position the middle section of the spring into the groove of the front case pivot boss and push to lock the upper end of the assist spring behind the front case spring anchor tab.
6. Using the special tools and a suitable press, install the needle bearing.
7. Using the special tools and a suitable press, install the sleeve bearing.
8. Install the sun gear, the thrust plate, and the snap ring.
9. Install the input shaft assembly and the thrust washer.
10. Using a suitable press, install the bearing.
11. Install the snap ring.
12. Using the special tool, install the oil seal.
13. Install the large snap ring in the groove in the front adapter.
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. Apply a 3 mm (1/8 inch) bead of silicone sealant to the front adapter mounting surface, then position the front adapter on the transfer case, and install the six bolts.
16. Attach the front case to the special tool.
17. Install the new shift fork facings. Verify that they snap securely into place.
18. Install the reduction hub and the reduction fork assembly as an assembly.
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. Make sure the external splines of the output shaft engage the internal splines of the lockup hub. Make sure the oil pump retainer arm and the oil filter leg are in the groove and notch of the front case.
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. Assemble the lockup assembly.
30. Press downward on the lockup hub and install the snap ring.
31. Install the lockup fork and the lockup collar as an assembly.
32. The triangular shaft will be in the two-wheel high (2H) position at final assembly.
33. Install the shift collar hub and the return spring.
34. Using the special tools, press the needle bearing into the housing.
35. Using the special tools, press the bearing into the housing.
36. Install the snap ring that retains the bearing to the transfer case cover.
37. Apply a 3 mm (1/8 in) bead of silicone sealant to the mating surface of the front case.
38. Assemble the cases. Align the output shaft, the shift shaft, and the return spring to their respective bores in the transfer case cover.
39. Install the bolts.
40. Install the bolts.
41. Install the spacer on the rear output shaft.
42. Using the special tool, install the oil seal.
43. Position the flange on the rear output shaft.
44. Install a new oil seal in the flange.
45. Using the special tool, install the flange, the washer and a new nut. Tighten the new nut on the special tool to 54 Nm (40 lb-ft) to seat the flange on the shaft.
46. Use the special tool to prevent the flange from turning. Install the new washer and the new nut.
47. Install the transfer case. For additional information, refer to «TRANSFER CASE»(ref-204990-S02270946012005111600000) .

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1. With the vehicle in NEUTRAL, raise and support the vehicle.
2. Remove the skid plate.
3. If the transfer case is being disassembled, remove the drain plug and drain the fluid. Install the drain plug when all of the fluid has drained.
4. 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.
5. Remove the rear driveshaft. For additional information, refer to «DRIVE SHAFTS»(ref-153359) .
6. Position a high lift jack under the transfer case.
7. 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, and clean the mating surfaces.

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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 AND FILLING»(ref-204990-S42937071062005111600000) .
3. Adjust the shift linkage. Raise the shift boot to expose the top surface of the cam plate. Loosen the bolts approximately one turn. Move the transfer case shift lever to the 4L position (lever in rearmost position on the cam plate). Rotate the cam plate clockwise around the center bolt until the bottom chamfered corner of the neutral lug just contacts the forward right edge of the shift lever. Hold the cam plate in this position and tighten the bolt first to 108 Nm (80 lb-ft). Tighten the second bolt to 49 Nm (36 lb-ft). Move the transfer case in-cab shift lever to all shift positions to check for positive engagement. There should be clearance between the shift lever and cam plate in the 2H front, 4H rear. Clearance should not exceed 3.30 mm (0.13 in), and 4L shift positions.