transfer case, electronic shift

Transfer Case, Electronic Shift

Disassembly

1. Remove the transfer case (7A195) from the vehicle as outlined, and place on workbench.

2. Using a 30mm (1.18-inch) thin-wall socket, first remove the rear output nut, case yoke (7B214), yoke to flange seal (7B215), then the output shaft yoke washer (7B368).

Transfer Case, 13-54 Electronic Shift, Disassembled View

Section 07-07C: Transfer Case, Electronic Shift 1996 Aerostar/Ranger/Explorer Workshop Manual

DISASSEMBLY AND ASSEMBLY Procedure revision date: 05/18/2000

SPECIAL SERVICE TOOL(S) REQUIRED

Description Tool Number

Input Shaft Bearing Remover T91T-7127-A

Impact Slide Hammer T50T-100-A

Axle Bearing/Seal Plate T75L-1165-B

Pinion Bearing Cone Replacer T53T-4621-C

Output Shaft Bearing Replacer T83-7025-B

Driver Handle T80T-4000-W

Output Shaft Bearing Replacer T83T-7065-B

Input Shaft Bearing Replacer T91T-7127-B

Input Shaft Bushing/Bearing Replacer T87T-7127-A

Front Shaft Needle Bearing Replacer T83T-7127-A

Item Part Number Description

1 7050 Main Drive Gear Bearing Retainer (1)

2 7917 Ring, Retaining (1)

3 7025 Bearing (1)

4 7A385 Output Shaft Thrust Washer (1)

5 7C122 Snap Ring (1)

6 7B066 Thrust Plate (1)

of 151996 Aerostar/Ranger/Explorer

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7 7D063 Sun Gear (1)

8 7A398 Front Planet (1)

9 7017 Input Shaft (1)

10 7A443 Bolt, Hex-Head (M10 x 1.5 x 30.0) (15)

11 383976 Barb, Breather (1)

12 7045 Nut, Metric (2)

13 7B368 Output Shaft Yoke Washer (2)

14 7052 Seal, Oil (2)

15 7B214 Yoke Assembly (1)

16 7005 Case (2)

17 7L027 Oil Pan Magnet (1)

18 — Fork, Reduction Shift (1) (Part of 7298)

19 7100 High-Low Collar (1)

20 7061 Shaft, Rear Output (1)

21 7A149 Pump Assembly (1)

22 382846 Clamp, Hose (1)

23 7A098 Strainer, Oil (1)

24 7A210 Hose, Coupling (1)

25 7177 Sprocket, Drive (24T) (1)

26 7106 Lockup Collar (1)

27 7D126 Spring, Sleeve Return (1)

28 7D164 Lockup Hub (1)

29 7917 Snap Ring (1)

30 7G362 Housing, Clutch (1)

31 — Tag, Identification (1) (Part of 7003)

32 17285 Speedometer Drive Gear (1)

33 7B215 Yoke to Flange Seal (1)

34 7B214 Case Yoke (2)

35 N800670 Bolt, Hex-Head (3)

36 7K470 Bracket, Speed Sensor and Wiring Harness (1)

37 — Wire Connector Spacer (Part of 7G360)

38 7G360 Transfer Case Shift Motor (1)

39 N802503 Bolt, Hex-Head (1)

40 87675 Plug, Pipe (1/2-14) (Not Serviced as Part of Index No. 17) (2)

41 — Broadcast Code Decal (Part of 7005)

42 7240 Shift Rail (1)

43 7219 Lockup Return Spring (1)

44 7289 Fork, Lockup (1)

45 7Z112 Spacer (1)

46 7F063 Cam, Electric Shift (1)

47 7W074 Spring, Torsion (1)

48 7N095 Shaft, Shift (1)

49 7917 Snap Ring (1)

50 7119 Thrust Washer (1)

51 7177 Sprocket, Driven (24T) (1)

52 7061 Output Shaft, Front (1)

53 7A029 Chain, Drive (1)

54 — Pin, Spiral (1) (Part of 7050)

55 7917 Snap Ring (1)

56 7025 Bearing (1)

57 7065 Output Shaft Bearing (1)

58 7B362 Pin, Spring (1)

59 7C430 Facing, Shift Fork (2)

60 — Pin, Dowel (2)

61 7917 Snap Ring (1)

62 7A153 Ring Gear (1)

63 7G361 Coil Assembly, Clutch (1)

64 7917 Snap Ring (1)

65 7025 Bearing (1)

66 N620480 Nut, Hex (3)

67 7W073 Bearing, Sleeve-Self Lube (1)

68 7B216 Seal, Oil (1)

69 7127 Bearing, Needle Front Output (1)



3. Using a 30mm (1.18-inch) thin-wall socket, remove the front output nut, then the output shaft yoke washer, rubber seal and case yoke.

4. Remove the two bolts from the connector bracket and remove the bracket.

5. Remove the brown wire from the No. 8 position in the connector by grasping the back plate of the connector body and pulling.

6. Remove the remaining bolt retaining the transfer case shift motor (7G360) to the rear case (7005) and remove the transfer case shift motor. Note the position of the triangular shaft extending out of the rear case and the triangular slot in the transfer case shift motor.

7. CAUTION: When removing the RTV sealant, use care n ot to damage the mating surfaces of the rear case a nd motor mounting face.

Remove all traces of RTV gasket sealant from the mating surfaces of the rear case and the motor mounting face.

8. CAUTION: The transfer case shift motor is serviced as a complete assembly. Do not remove the screws t hat secure the rear case to the motor gear housing.

Remove the nine bolts that retain the front case to the rearcase. Make sure that the front case is facing downward so that the rear cover is facing upwards. Insert a 13mm (1/2-inch) drive breaker bar between the pry bosses and separate the front case from the rear case. Remove all traces of RTV Gasket Sealant from the mating surfaces of the front case and rear case.

9. If the speedometer drive gear (17285) is to be replaced, first remove the yoke to flange seal by prying and pulling the yoke to flange seal or use the Impact Slide Hammer T50T-100-A to pop off the yoke to flange seal. Do not damage the bearing, bearing cage or case. Remove the speedometer drive gear.

10. If the rear output shaft bearing (7025) requires replacing, remove the internal snap ring that retains the bearing in the bore. From the outside of the case, drive out the bearing using Step Plate D80L-630-3 or equivalent and a drift.

Pin Number Circuit Circuit Function

1 770 (W) Electrical Shift 4x4 Module to Motor Position B

2 764 (BR/W) Electrical Shift 4x4 Module to Motor Position C

3 763 (O/W) Electrical Shift 4x4 Module to Motor Position D

4 777 (Y) Electrical Shift 4x4 Module to Motor Control Counterclockwise

5 772 (P/Y) Electrical Shift 4x4 Module to Motor Position A

6 762 (Y/W) Electrical Shift 4x4 Module to Motor Position Return

7 778 (O) Electrical Shift 4x4 Module to Motor Control Clockwise

8 779 (BR) Electrical Shift 4x4 Module to Electric Clutch



11. If required, remove the front output needle bearing from the rear case with Puller Collet D80L-100-S or equivalent and Impact Slide Hammer T50T-100-A.

12. Remove the three nuts retaining the clutch coil assembly to the rear case. Pull the assembly, along with the O-rings and brown wire, from the case.

13. Remove the lockup return spring from the boss on the fork.

14. Remove the clutch housing from the output shaft.



15. Remove the 2W-4W lockup and the 2W-4W shift fork as an assembly. Remove the shift fork from the lockup.

16. Pull out the shift rail.

17. If disassembly of the 2W-4W lockup is required, remove the internal snap ring and pull the lockup hub and sleeve return spring from the lockup collar.

18. Remove the helical cam from the front case. If required, remove the helical cam, torsion spring and sleeve from the shaft.

19. Remove the external snap ring and thrust washer (7119) that retains the driven sprocket to the front output shaft.

20. Remove the chain, driven sprocket and drive sprocket as an assembly.



21. CAUTION: If there is removal resistance, do not po und or use force to disassemble the pump; start ove r again.

Remove the oil pan magnet (7L027) from the slot in the front of the case bottom. Remove the output shaft and oil pump as an assembly.

22. If required, rotate the pump to align the cover keyway to pin of the output shaft and pull the pump straight out.

23. If required to replace the oil pump drive pin, perform the following.

a. Measure and record the drive pin height above (sticking out from) the diameter of the output shaft. This information will be required during installation. b. Remove the drive pin from the output shaft.

24. Remove the front output shaft.

25. Remove the high-low range shift fork and collar as an assembly.

26. Turn the front case over and remove the six bolts (7A443) retaining the main drive gear bearing retainer (7050) to the front case. Remove the main drive gear bearing retainer, input shaft (7017) and front planet (7A398) as an assembly.

27. Expand the tangs of the large snap ring in the main drive gear bearing retainer. With the input shaft against a bench, push the main drive gear bearing retainer down and slide the main drive gear bearing retainer off the bearing. Lift the input shaft and front planet from themain drive gear bearing retainer.



28. If required, remove the input yoke to flange seal from the main drive gear bearing retainer using Impact Slide Hammer T50T-100-A to pop off the yoke to flange seal. Do not damage the bearing, bearing cage or case.

29. Remove the internal snap ring from the planetary carrier and separate the front planet from the input shaft.

30. Remove the external snap ring from the input shaft. Place the input shaft in a vise and remove the bearing with Bearing Pulling Attachment D79L-4621-A or equivalent. Remove the thrust washer, thrust plate and the sun gear off the input shaft.

31. NOTE: Under normal use, the needle bearing and bush ing should not require replacement. If replacement is required, the bushing and needle bearing must be replaced as a set.

Inspect the bushing and needle bearing in the end of the input shaft for wear or damage.

32. If replacement of the needle bearing and bushing is required, press the bearing and bushing out as follows:

a. Position the input shaft on Axle Bearing/Seal Plate T75L-1165-B or equivalent, and using Pinion Bearing Cone Replacer T53T-4621-C as a spacer. b. Insert Input Shaft Bearing Remover T91T-7127-A into the input shaft so it is resting on top of the bearing cage. c. Tighten the actuator pin until it stops, then press the bearing and bushing out together.

33. If required, remove the ring gear (7A153) from the front case half using a press. Note the relationship of the serrations to the chamfered pilot diameter during removal.

34. If required, remove the front yoke to flange seal using Impact Slide Hammer T50T-100-A to pop off the yoke to flange seal. Do not damage the bearing, bearing cage or case.

35. If required, remove the internal snap ring retaining the front output shaft ball bearing and remove the bearing using Step Plate D80L-630-3 or equivalent with a drift.



Assembly

Before assembly, lubricate all parts with MERCON® Multi-Purpose Automatic Transmission Fluid XT-2-QDX or -DDX or equivalent.

1. If removed, drive the bearing into the front output case bore using Output Shaft Seal Replacer T83T-7025-B and Driver Handle T80T-4000-W. Drive the bearing in straight, making sure it is not cocked in the bore. Install the internal snap ring that retains the bearing to the front case.

2. If removed, install the front yoke to flange seal in the front case bore using Output Shaft Seal Replacer T83T-7065-B and Driver Handle T80T-4000-W.

3. If removed, install the ring gear in the front case. Align the serrations on the outside of the ring gear to the serrations previously cut in the front case bore. Using a press, start the piloted chamfered end of the ring gear first and press in until it is fully seated. Make sure that the ring gear is not cocked in the bore.

4. If removed, install the input yoke to flange seal into the mounting adapter bore. Use Output Shaft Seal Replacer T83T-7065-B and Driver Handle T80T-4000-W.

5. NOTE: If the input shaft needle bearing and bushing were removed, install a new bearing and bushing as detailed in the following steps:

Press a new needle bearing, then a new bushing in the input shaft as follows:

a. Position the input shaft on Axle Bearing/Seal Plate T75L-1165-B or equivalent, and Pinion Bearing Cone Replacer T53T-4621-C as a spacer. b. Using Input Shaft Bearing Replacer T91T-7127-B, press a new needle bearing into the end of the input shaft until it seats in the input shaft

c. Press in a new bushing using Input Shaft Bushing/Bearing Replacer T87T-7127-A.



6. NOTE: The recessed face of the sun gear and the sna p ring groove on the bearing outer race should be t oward the rear of the transfer case. The stepped fa ce of the thrust washer should face toward the bearing.

Slide the sun gear, thrust plate and thrust washer into position on the input shaft. Press the bearing over the input shaft. Install the external snap ring to the input shaft.

7. Install the front planet to the sun gear and input shaft. Install the internal snap ring to the planetary carrier.

8. Place the tanged snap ring in the mounting adapter groove. Using Axle Bearing/Seal Plate T75L-1165-B place the input shaft and front planet in the main drive gear bearing retainer and expand the tanged snap ring while pushing inward until the front planet and input shaft are seated in the main drive gear bearing retainer. When properly seated, the tanged snap ring will snap into place. Check installation by holding the main drive gear bearing retainer by hand and carefully tapping the face of the input shaft against a wooden block to make sure that the snap ring is engaged.

9. Remove all traces of RTV Gasket Sealant from the front case and mounting adapter mating surfaces. Install a bead of RTV Gasket Sealant on the surface of the front case. Use Non-Acid Cure Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M4G273-A.

10. Position the main drive gear bearing retainer on the front case. Install the six bolts and tighten to 31-41 Nm (23-30 lb-ft).

11. NOTE: Make sure that the nylon wear pads are instal led on the shift fork and snapped securely into pla ce.

Install the high-low shift fork and high-low collar as an assembly into the front planet.


1 7917 External Snap Ring

2 7A385 Thrust Washer

3 7B066 Thrust Plate

4 7017 Input Shaft

5 7D063 Sun Gear

6 7C122 Internal Snap Ring

7 7025 Bearing



12. If removed, press the pin into the rear output shaft pin hole to the same height or 1mm (0.040 inch) minimum above the diameter of the output shaft.

13. NOTE: Do not disassemble oil pump. It is serviced o nly as an assembly.

NOTE: Do not remove the plastic insert from the bor e of the new pump. Discard it after it slides out d uring pump installation to the rear output shaft.

NOTE: While turning the output shaft, prime the pum p through the oil filter pickup tube or housing inl et hole with clean Motorcraft MERCON® Multi-Purpose Automatic Transmission Fluid XT-2-QDX or -DDX or equivalent.

If the pump does not turn freely after installation to the rear output shaft, realign the cover keyway to the pin of the rear output shaft and jiggle the pump until it fully seats and rotates freely.

If new pump is used, slide the pump housing slot onto the pin of the output shaft with the retaining arm of the cover toward the rear of the case. If the pump does not turn freely, follow the instructions as listed in the previous paragraph.

Inspect the outside surfaces and bore of the oil pump. If there is no discoloration in the pump housing, gear or cover, and the pump bore and the lube holes of the output shaft show evidence of oil, the pump is working. Hand align the keyways and bores of the housing, gear and cover and slide the pump onto the rear output and fifth gear driveshaft pin with the retaining arm of the cover toward the rear of the case.

14. Install the output shaft and oil pump in the input shaft. Make sure that the internal splines of the output shaft engage the internal splines of the high-low shift collar. Make sure that the oil pump retainer arm and oil filter leg are in the groove and slot of the front case.

15. Install the oil pan magnet in the slot in the front case just above the oil filter leg.


1 7061 Output Shaft Rear

2 7A149 Pump Body

3 382846 Clamp

4 7A210 Hose

5 7A098 Filter/Pickup



16. Install the front output shaft in the front case.

17. If disassembled, assemble the 2W-4W lockup assembly. Install the sleeve return spring into the bore of the lockup collar with the large end installed first. Place the lockup hub over the spring and install the lockup hub into the lockup collar. Install the internal snap ring.

18. NOTE: The driven sprocket (on the front output shaf t) must be installed with the marking REAR facing t oward the rear case, if so marked.

Install the chain, drive sprocket and driven sprocket as an assembly over the output shaft.

Install the thrust washer on the front output shaft and install the external snap ring over the thrust washer to retain the driven sprocket.

19. Slide the spring spacer on the camshaft and position it beneath the drive tang. Place the torsion spring on the camshaft. Position the first spring tang to the left of the camshaft drive tang (View A). Wind the second spring tang clockwise past the drive tang (View B). Push the torsion spring and sleeve in as far as it will go (View C). This will seat the second spring tang on the right side of the drive tang. Install the helical cam and slide the drive tang between the torsion spring tangs as far as it will go.

20. CAUTION: Do not bend the helical cam during instal lation to the front case because of possible damage to the pin at the tang end of the motor shaft.

Install the pin on the tang end of the helical cam into the hole in the front case. Position the torsion spring tangs so that they are pointing toward the top side of the transfer case and just touching the high-low shift fork.



21. Install the shift rail through the high-low shift fork and make sure that the shift rail is seated in the front case bore.

22. Install the 2W-4W shift fork to the 2W-4W lockup. Install the 2W-4W lockup and shift fork over the output shaft and onto the shift rail.

23. NOTE: After the 2W-4W shift fork is released, the 2 W-4W fork roller bushing should rest on the top sur face of the helical cam and not into an inside trac k.

NOTE: The triangular shaft will be in the two wheel high (2H) position at final assembly.

Lift the 2W-4W shift fork slightly while holding the shift rail down and rotate the helical cam track into the high-low fork roller bushing by turning the helical cam.

24. Install the clutch housing on the output shaft with the cavity side or notches facing the rear case.

25. If removed, drive the front output shaft needle bearing into the rear cover bore with Front Shaft Needle Bearing Replacer T83T-7127-A and Driver Handle T80T-4000-W.



26. If removed, install the rear output bearing in the rear case bore. Drive the bearing into the rear case bore with Output Shaft Bearing Replacer T83T-7025-B and Driver Handle T80T-4000-W. Make sure that the bearing is not cocked in the bore. Install the internal snap ring that retains the bearing to the rear case.

27. CAUTION: Do not kink or trap the wire while seatin g the clutch coil to the case.

Apply a bead of Non-Acid Cure Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M4G273-A to the base of the clutch coil studs and grommet. Install the clutch coil from inside the rear case until the wire and studs extend through the cover. Install the nuts and tighten to 8-11 Nm (71-97 lb-in).

28. Coat the mating surface of the front case with a bead of Non-Acid Cure Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M4G273-A.

29. Install the lockup return spring to the shift rail and shift fork with the spring mounted in a vertical position.



30. The following procedure must be followed prior to installing the rear case onto the front case half:

a. Align the output shaft with the rear case output shaft bore. b. Align the helical cam with the rear case motor bore. c. Align the rear case so that the spring boss engages the lockup return spring and shift rail.

If difficulty is encountered with seating the rear case, tap the rear output shaft with a sharp blow using a rubber mallet in a direction away from the triangular shaft while pushing down on the rear case.

31. Install the bolts retaining the case halves and tighten to 31-41 Nm (23-30 lb-ft).

32. NOTE: If the shaft will not stay in the 4H position , rotate the shaft clockwise to the 2H position. Du ring motor installation, rotate the transfer case s hift motor counterclockwise until the transfer case shift moto r is aligned with the mounting holes.

Using pliers equipped with soft jaws, rotate the triangular shaft so it is aligned with the triangular slot in the transfer case shift motor.

33. NOTE: Do not loosen the two nuts or studs that atta ch the motor end cap to the motor housing.

Slightly loosen the two nuts that attach the slotted support bracket to the end of the motor house.

34. Apply Black Non-Acid Cure Silicone Rubber E7TZ-19562-A meeting Ford specification ESL-M4G273-A to motor housing base and install on transfer case.

35. NOTE: The wire harness must be routed as shown to p rovide clearance and to prevent the wire harness fr om grounding the damper.

Install the transfer case shift motor and three bolts. Tighten to 8-11 Nm (71-97 lb-in).

36. Holding the slotted support bracket tight against the motor housing end, secure the bracket to the transfer case, tightening the bolt with lockwasher to 8-11 Nm (71-97 lb-in).

37. Retighten the two nuts that attach the slotted support bracket to the end of the motor to 3-4 Nm (27-35 lb-in).

38. Install the brown clutch coil wire to the No. 8 terminal. Install the red locking sleeve.



39. Install the speedometer drive gear to the rear case bore. Drive the yoke to flange seal into the rear case bore with Output Shaft Seal Replacer T83T-7065-B and Driver Handle T80T-

4000-W.

40. Install the rear case yoke on the output shaft. Install the rubber seal, output shaft yoke washer and nut. Tighten the nut to 339-381 Nm (250-280 lb-ft).

41. Install the drain plug and tighten to 19-30 Nm (14-22 lb-ft).

42. Install the front case yoke, rubber seal, output shaft yoke washer and the nut to front output shaft. Tighten the nut to 250-275 Nm (184-203 lb-ft).

43. Place a 3/8-inch drive ratchet in the fill plug and remove the plug. Fill the transfer case with 1.2 liters (2.5 U.S. pints) of Motorcraft MERCON® Multi-Purpose Automatic Transmission Fluid XT-2-QDX or -DDX or equivalent.

44. Install the fill plug and tighten to 19-30 Nm (14-22 lb-ft).

45. Install the transfer case as outlined in the Installation portion of this section.

Pin Number Circuit Circuit Function

1 770 (W) Electrical Shift 4x4 Module to Motor Position No. 4

2 764 (BR/W) Electrical Shift 4x4 Module to Motor Position No. 3

3 763 (O/W) Electrical Shift 4x4 Module to Motor Position No. 2

4 777 (Y) Electrical Shift 4x4 Module to Motor Control Counterclockwise

5 771 (P/Y) Electrical Shift 4x4 Module to Motor Position No. 5

6 762 (Y/W) Electrical Shift 4x4 Module to Motor Position No. 1

7 778 (O) Electrical Shift 4x4 Module to Motor Control

8 779 (BR) Electrical Shift 4x4 Module to Electric Clutch



transfer case, electronic shift

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