Transfer Case - 2-Speed Torque-On-Demand: Notes
WARNING: This page is about a different car, the 2009 Mercury Mountaineer, 2009 Ford Explorer Sport Trac, and 2009 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools
| Illustration | Tool Name | Tool Number |
|---|---|---|
| Remover, Bearing Cup | 308-047 (T77F-1102-A) | |
| Installer, Wheel Hub Bearing Cup | 204-020 (T73T-1202-A) | |
| Puller, Bearing | 205-D064 (D84L-1123-A) or equivalent | |
| Remover, Stator Bearing | 307-318 (T94P-77001-KH) | |
| Holding Fixture, Drive Pinion Flange | 205-126 (T78P-4851-A) | |
| Installer, Differential Bearing Cup | 308-163 (T88C-77000-FH) | |
| Adapter for 303-224 (Handle) | 205-153 (T80T-4000-W) | |
| Holding Fixture, Transmission | 307-003 (T57L-500-B) | |
| Slide Hammer | 100-001 (T50T-100-A) | |
| Installer, Input Shaft Bearing | 308-085 (T83T-7025-C) | |
| Installer, Input Shaft Oil Seal | 308-186 (T90T-7127-B) | |
| Remover, Bushing | 307-001 (TOOL-1175-AC) or equivalent | |
| Remover, Output Shaft Flange | 307-523 or equivalent | |
| Remover, Oil Seal | 303-409 (T92C-6700-CH) | |
| Installer, Valve Stem Oil Seal | 303-367 (T90P-6510-AH) |
Material
| Item | Specification |
|---|---|
| Motorcraft Transfer Case Fluid XL-12 |
- |
| Silicone Gasket and Sealant TA-30 |
WSE-M4G323-A4 |
| Threadlock and Sealer TA-25 |
WSK-M2G351-A5 |
| Item | Part Number | Description |
|---|---|---|
| 1 | 7177 | Drive sprocket |
| 2 | 7A029 | Drive chain |
| 3 | 7Z112 | Thrust washer |
| 4 | - | Oil pump assembly |
| 5 | 7061 | Rear output shaft |
| 6 | 7100 | High-low collar |
| 7 | 7A398 | Front planetary gear set assembly |
| 8 | 7017 | Input shaft |
| 9 | 7N062 | Hub |
| 10 | 7127 | Bearing |
| 11 | 7917 | Snap ring |
| 12 | 7C108 | Clutch pack assembly |
| 13 | 7H150 | Valve assembly |
| 14 | 7917 | Snap ring |
| 15 | 7G159 | Wave spring |
| 16 | 7R428 | Apply cam |
| 17 | 7A534 | Balls (3 required) |
| 18 | 7G362 | Cam and coil housing assembly |
| 19 | 7G361 | Clutch coil assembly |
| 20 | 7A443 | Thrust bearing |
| 21 | 7025 | Front output shaft rear bearing |
| 22 | 7045 | Clutch coil nut (3 required) |
| 23 | 7G450 | Wheel |
| 24 | 7B215 | Yoke-to-flange oil seal |
| 25 | 7B214 | Rear output shaft flange |
| 26 | 7052 | Output flange oil seal |
| 27 | 7B368 | Output shaft flange washer |
| 28 | 7045 | Rear output shaft flange nut |
| 29 | - | Electrical connector |
| 30 | N800670-S | Shift motor bolt (3 required) |
| 31 | 7G360 | Transfer case shift motor |
| 32 | 7288 | Shifter shaft seal |
| 33 | 7A443 | Transfer case bolt (17 required) |
| 34 | 7005 | Rear transfer case |
| 35 | 7F063 | Electric shift cam, torsion spring and shift shaft assembly |
| 36 | 7240 | Shift rail |
| 37 | 7289 | Reduction shift fork |
| 38 | 7917 | Snap ring |
| 39 | 7L027 | Oil pan magnet |
| 40 | 7A153 | Ring gear |
| 41 | 7005 | Transfer case cover (4.0L with 5R55) |
| 42 | 7B215 | Oil seal |
| 43 | 7B215 | Oil seal |
| 44 | 7061 | Output shaft and flange (front) (4.0L with 5R55) |
| 45 | 7061 | Output shaft and flange (front) (4.6L with 6R60) |
| 46 | 7B215 | Oil seal |
| 47 | 7B215 | Oil seal |
| 48 | 7005 | Transfer case cover (4.6L with 6R60) |
| 49 | 7025 | Bearing |
| 50 | 7917 | Snap ring |
| 51 | - | Spacer |
| 52 | 7177 | Driven sprocket |
| 53 | 7025 | Bearing |