308-07B-1 308-07B-1Transfer Case

DISASSEMBLY AND ASSEMBLYSpecial Tool(s)Transfer Case — Electronic Shift

Installer, Input Shaft Oil Seal308-186 (T90T-7127-B)Special Tool(s)

Remover, Bearing Cup308-047 (T77F-1102-A)

Universal Blind Hole Puller Set303 DS005 (D80L-100-A)

Installer, Bearing Cup308-017 (T73T-4222-B)

Installer, Mainshaft Bearing308-060 (T77J-7025-K)

Remover, Stator Bearing307-318 (T94P-77001-KH)

Installer, Input Shaft Bearing308-085 (T83T-7025-C)

Adapter for 303-224 (Handle)205-153 (T80T-4000-W)

Installer, Input Shaft Oil Seal308-249 (T96T-7127-A)

Holding Fixture, Transmission307-003 (T57L-500-B)

Protector, Shaft Oil Seal308-251 (T96T-7127-C)

Slide Hammer100-001 (T50T-100-A)

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Copyright 2005, Ford Motor CompanyLast updated: 1/12/2006 2006 F-150, Mark LT, 9/2005

308-07B-2 308-07B-2Transfer Case

DISASSEMBLY AND ASSEMBLY (Continued)

Special Tool(s) Material

Remover, Oil Seal Item Specification303-409 (T92C-6700-CH) Ultra Silicone Sealant —

TA-29

MERCON Multi-Purpose MERCONAutomatic TransmissionFluidXT-2-QDX (US);XT-2-LM12 (Canada)

Installer, Valve Stem Oil Seal303-367 (T90P-6510-AH)

2006 F-150, Mark LT, 9/2005

308-07B-3 308-07B-3Transfer Case

DISASSEMBLY AND ASSEMBLY (Continued)

Transfer Case Exploded View — Electronic Shift

2006 F-150, Mark LT, 9/2005

308-07B-4 308-07B-4Transfer Case

DISASSEMBLY AND ASSEMBLY (Continued)

2006 F-150, Mark LT, 9/2005

308-07B-5 308-07B-5Transfer Case

DISASSEMBLY AND ASSEMBLY (Continued)

Item Part Number Description Item Part Number Description

41 7A443 Bolt1 7917 Snap ring

42 N62048C-S2 Nut2 7A153 Ring gear

43 7A010 Case plug3 7064 Snap ring

44 7G360 Transfer case shift motor4 7A398 Front planet carrier

45 — J-clip (part of 7G360)5 7120 Needle bearing

46 N800670-S Bolt6 7065 Bushing

47 — Wire connector spacer (part7 7100 Reduction hubof 7G360)8 7A149 Oil pump assembly

48 7A443 Bolt9 7177 Drive sprocket49 7288 Shifter shaft seal10 7106 Lockup collar50 — Bar code label (part of 7005)11 7D126 Spring51 7A010 Case plug12 7D164 Lockup hub52 7025 Bearing13 — Hose clamp53 7N063 Spacer14 9324 Hose (cut from fuel tube54 7A443 Bolthose)

55 — Sealing ring (part of 7085)15 7A098 Lube pickup and filter

56 7B215 Yoke to flange seal16 7E290 Magnet

57 7F293 Shipping plug17 7025 Bearing

58 — Bushing (part of 7085)18 7917 Snap ring

59 7085 Extension housing19 7177 Driven sprocket

60 — Wire convolute (part of 7085)20 7A029 Drive chain assembly

61 — Identification tag (part of21 — Dowel (part of 7005)7085)22 7C207 Case stud

62 7F063 Shift cam assembly23 7B215 Input flange seal63 7240 Shift rail24 7C016 Shield64 7219 Lockup fork spring25 7061 Front output shaft with shield65 7289 Lockup fork26 7034 Breather barb66 7289 Reduction shift fork assembly27 7B215 Yoke to flange seal67 7C430 Shift fork pad28 7005 Case

29 7N281 Input snap ring Disassembly30 7025 Bearing

31 7061 Output shaft CAUTION: Discard all seals after32 7F135 Spring removing them.33 7H150 Armature

1. Remove the transfer case. For additional34 7917 Snap ringinformation, refer to Transfer Case —35 7G362 Hub and coil housingElectronic Shift in this section.36 7917 Snap ring

37 7G361 Coil2. WARNING: Wear protective eyewear

38 7025 Bearing whenever using compressed air.39 7917 Snap ring

Clean the transfer case with solvent and dry40 7005 Case with compressed air.

(Continued)

2006 F-150, Mark LT, 9/2005

308-07B-6 308-07B-6Transfer Case

DISASSEMBLY AND ASSEMBLY (Continued)

4. If not done previously, remove the drain plug3. WARNING: Make sure the special tooland drain the fluid.lock pin is secure.

Using the special tool, secure the transfer caseto the bench.

5. Review the transfer case symptom chart beforeand during the disassembly procedure.

Electronic Shift Transfer Case Symptom Chart

Condition Possible Source(s) Action

• Fluid contaminated • Seal failure (items 23, 27, 49, 56). • INSPECT seals for signs of ingress(plastic/metallic) • Oil pump assembly (item 8). or egress. If metal and plastic

contamination is noted when thefluid is drained, OPEN transfercase and INSPECT internalcomponents for wear. INSTALLnew components as necessary,including the transfer case pump.VERIFY correct operation of allcomponents prior to reassembly.All contamination should becleaned from the components. Allbearings should be inspected forsmooth operation.

• Jumps out of four wheel drive • Lockup fork (item 65). • INSPECT internal shift system for(4WD) (even when shift motor • Reduction shift fork assembly (item damage or wear. Shift forks andremoved) 66). shift fork pads should be inspected

• Shift cam assembly (item 62). for wear or damage. If signs of• Lockup hub assembly (item 12). heat generation are noted,• Oil pump assembly (item 8). INSTALL a new pump assembly

and INSTALL pump filter.INSPECT slip yokes and bushingsfor unusual wear.

• 4HI will not engage (when shift • Transfer case shift components: • INSPECT internal shift componentscam is positioned manually in 4H — Lockup fork (item 65). for wear. Shift forks and shift forkwith shift motor removed) — Lockup hub assembly (item 12). pads should be inspected for wear

— Shift cam assembly (item 62). or damage. If signs of heat— Reduction shift fork assembly generation are noted, INSTALL a

(item 66). new pump assembly and INSTALL• Oil pump assembly (item 8). pump filter. INSPECT slip yokes

and bushings for unusual wear.

2006 F-150, Mark LT, 9/2005

308-07B-7 308-07B-7Transfer Case

DISASSEMBLY AND ASSEMBLY (Continued)

Electronic Shift Transfer Case Symptom Chart (Continued)

Condition Possible Source(s) Action

• 4LO will not engage (when shift • Lockup fork (item 65). • INSPECT internal shift componentscam is positioned manually in 4L • Reduction shift fork assembly (item for wear. Shift forks and shift forkwith shifter linkage removed) 66). pads should be inspected for wear

• Reduction hub assembly (item 7). or damage. If signs of heat• Shift cam assembly (item 62). generation are noted, INSTALL a• Lockup hub assembly (item 12). new pump assembly and INSTALL• Oil pump assembly (item 8). pump filter. INSPECT slip yokes

and bushings for unusual wear.

• 4WD will not disengage (when • Transfer case shift components: • INSPECT internal shift componentsshift cam is positioned manually in — Lockup fork (item 64). for wear. Shift forks and shift fork2H with shifter motor removed) — Lockup Hub assembly (item pads should be inspected for wear

12). or damage. If signs of heat— Shift cam assembly (item 62). generation are noted, INSTALL a— Reduction shift fork assembly new pump assembly and INSTALL

(item 66). pump filter. INSPECT slip yokes• Oil pump assembly (item 8). and bushings for unusual wear.

• Not able to manually shift transfer • Transfer case shift components: • INSPECT internal shift componentscase — Lockup fork (item 65). for wear. Shift forks and shift fork

— Lockup hub assembly (item 12). pads should be inspected for wear— Shift cam assembly (item 62). or damage. If signs of heat— Reduction shift fork assembly generation are noted, INSTALL a

(item 66). new pump assembly and install• Oil pump assembly (item 8). pump filter. INSPECT slip yokes

and bushings for unusual wear.

• NVH • Loose driveshafts. • INSPECT system for loose screws• Loose screws or bolts. or bolts. TIGHTEN as required.• Drive chain (item 20). DRAIN fluid and INSPECT for• Front planet carrier (item 4). contamination. If heavy metallic or• Shift components. plastic contamination noted,

REMOVE transfer case andINSPECT for source ofcontamination. INSTALL a newcomponents as necessary. If signsof heat generation are noted,INSTALL a new pump assemblyand INSTALL pump filter.INSPECT driveshaft slip yoke andINSTALL new as required.

• Uncommanded shift • Transfer case shift components: • INSPECT internal shift components— Lockup fork (item 65). for wear. Shift forks and shift fork— Lockup hub assembly (item 12). pads should be inspected for wear— Shift cam assembly (item 62). or damage. If signs of heat— Reduction shift fork assembly generation are noted, INSTALL a

(item 66). new pump assembly and INSTALL• Shift fork pads worn: pump filter. INSPECT slip yokes

— Reduction hub assembly (item and bushings for unusual wear. 7).

2006 F-150, Mark LT, 9/2005

308-07B-8 308-07B-8Transfer Case

DISASSEMBLY AND ASSEMBLY (Continued)

Electronic Shift Transfer Case Symptom Chart (Continued)

Condition Possible Source(s) Action

• Rear output leak • Yoke to flange seal (item 56). • INSPECT yoke for damage or• Slip yoke damage or degradation. excessive wear. If wear noted on• Internal or external contamination. yoke, INSPECT transfer case rear

output bushing for damage.INSPECT transfer case seal fordamage or wear. INSPECT systemfor contamination. INSTALL a newslip yoke, transfer case bushingand/or seal as required.

• Transfer case overfull • Input flange seal (item 23). • CHECK transmission for low fluidcondition. If transmission fluidlevel OK, DRAIN and REFILLtransfer case to correct level. Iftransmission fluid level low,INSPECT the input flange seal fordamage.

• T-case is in a range/mode other • Transfer case shift components: • INSPECT internal shift componentsthan indicated by motor contact — Lockup fork (item 65). for wear. Shift forks and shift forkplates (uncommanded shift/jumps — Lockup hub assembly (item 12). pads should be inspected for wearout of gear) — Shift cam assembly (item 62). or damage. If signs of heat

— Reduction shift fork assembly generation are noted, INSTALL a(item 66). new pump assembly and INSTALL

• Oil pump assembly (item 8). pump filter. INSPECT slip yokesand bushings for unusual wear.

6. Using a suitable tool, remove the oil seal.

7. Remove the coil wire and the ground wire fromthe electric shift motor electrical connector.

• Remove the wire connector spacer.

• Remove the coil wire and pin.

• Remove the ground wire and pin.

X Use an electrical connector pin extractortool.

2006 F-150, Mark LT, 9/2005

308-07B-9 308-07B-9Transfer Case

DISASSEMBLY AND ASSEMBLY (Continued)

8. Remove the transfer case shift motor. 11. NOTE: The bolts are self-tapping, and it isnormal to find metal shavings while removing1 Remove the bolts.the cover.

2 Remove the transfer case shift motor.Remove the bolts.

9. Remove the extension housing.12. NOTE: Use pry bosses to separate the cover

1 Remove the 6 extension housing bolts. from the case.2 Remove the extension housing. Separate the transfer case covers.

10. Remove the rear output shaft snap ring. 13. Remove the coil.• Lift up on the output shaft while removing 1 Remove the 3 coil-to-cover nuts.

the snap ring.2 Remove the coil.

2006 F-150, Mark LT, 9/2005

308-07B-10 308-07B-10Transfer Case

DISASSEMBLY AND ASSEMBLY (Continued)

14. Using the special tools, remove the rear output 17. Remove the coil housing.shaft bearing.

18. Remove the shift fork.15. Using the special tools, remove the front output 1 Remove the lockup hub.

shaft bearing.2 Remove the shift fork and spring.

16. Remove the shift collar hub snap ring.

2006 F-150, Mark LT, 9/2005

308-07B-11 308-07B-11Transfer Case

DISASSEMBLY AND ASSEMBLY (Continued)

19. NOTE: Remove the lockup hub assembly as asingle unit. If disassembly is required, proceedwith the following.

Disassemble the lockup hub assembly.

1 Remove the lockup hub snap ring.

2 Separate the lockup collar.

3 Separate the 2 lockup springs.

4 Separate the lockup hub.

5 Remove the armature.

22. Remove the magnet from its slot in the case.

20. Remove the spacer.

23. NOTE: The pump assembly is not repairable.

Remove the oil pump and the output shaft as anassembly.

• Remove the oil pump from the output shaft.

21. Remove the drive chain and sprockets as anassembly.

2006 F-150, Mark LT, 9/2005

308-07B-12 308-07B-12Transfer Case

DISASSEMBLY AND ASSEMBLY (Continued)

24. Remove the shift rail.

28. CAUTION: Do not let the front planetcarrier fall while removing the snap ring.

25. Remove the shift fork and the reduction hub.Remove the front planet carrier.

1 Remove the shift fork.1 Remove the front planet carrier snap ring.

2 Remove the reduction hub.2 Remove the front planet carrier.

26. WARNING: Do not disassemble shift 29. If necessary, using the special tools, remove thecam assembly. bushing from the front planet.Remove the electric shift cam assembly.

27. Using the special tool, remove the input seal.

2006 F-150, Mark LT, 9/2005

308-07B-13 308-07B-13Transfer Case

DISASSEMBLY AND ASSEMBLY (Continued)

30. Using a drift and a hammer, remove the needle 33. CAUTION: Do not let the front outputbearing, if necessary. shaft fall while removing the snap ring.

Remove the front output shaft.

1 Remove the front output shaft snap ring.

2 Remove the front output shaft.

31. Remove the ring gear.

1 Remove the ring gear snap ring.

2 Remove the ring gear.

34. Using the special tools, remove the front outputshaft bearing.

32. Remove the front planet carrier bearing snapring. Then, using the special tools, remove thefront planet carrier bearing.

35. Using the special tools, remove the front yoketo flange seal.

2006 F-150, Mark LT, 9/2005

308-07B-14 308-07B-14Transfer Case

DISASSEMBLY AND ASSEMBLY (Continued)

36. Using a suitable pry tool, remove the electric 2. Using a suitable press and the special tools,shift motor seal. install the front output shaft bearing.

37. Remove the dust shield, if necessary. 3. Using the special tool, install the front yoke toflange seal.

Assembly4. Install the dust shield, if removed.

1. CAUTION: Do not crush the seal.

Using the special tool, install the electric shiftmotor seal.

2006 F-150, Mark LT, 9/2005

308-07B-15 308-07B-15Transfer Case

DISASSEMBLY AND ASSEMBLY (Continued)

5. Install the front output shaft.

1 Position the front output shaft.

2 Install the front output shaft snap ring.

9. Install the front planet carrier.

1 Position the front planet carrier.

2 Install the front planet carrier snap ring.

6. Using a press and a suitable bearing installer,install the front planet carrier bearing. Installthe front planet carrier bearing snap ring.

10. Using the special tools, install the input seal.

7. Install the ring gear.

• Position the ring gear.

• Install the ring gear snap ring.

8. CAUTION: Do not crush the needlebearings.

If removed, using a suitable press and thespecial tool, install the needle bearing andbushing into the front planet carrier.

2006 F-150, Mark LT, 9/2005

308-07B-16 308-07B-16Transfer Case

DISASSEMBLY AND ASSEMBLY (Continued)

11. Install the electric shift cam assembly. 14. Install the oil pump and the output shaft.

12. Install the shift fork and the reduction hub. 15. Install the magnet into its slot in the case.

13. Install the shift rail. 16. Install the drive chain and sprocket assembly.

2006 F-150, Mark LT, 9/2005

308-07B-17 308-07B-17Transfer Case

DISASSEMBLY AND ASSEMBLY (Continued)

17. Install the spacer.

20. Install the coil housing.

18. NOTE: If the lockup hub assembly wasdisassembled, carry out the following steps.

Assemble the lockup hub assembly.

1 Position the lockup collar.

2 Install the lockup collar springs.

3 Install the lockup hub.

4 Install the armature.

5 Install the lockup hub snap ring.

21. Install the snap ring.

19. Install the lockup hub and the shift fork andspring.

2006 F-150, Mark LT, 9/2005

308-07B-18 308-07B-18Transfer Case

DISASSEMBLY AND ASSEMBLY (Continued)

22. Using the special tool, install the rear output 24. Install the coil.shaft bearing. 1 Position the coil.

2 Install the nuts.

X Tighten to 10 Nm (89 lb-in).

23. Using the special tool, install the front outputshaft bearing.

25. CAUTION: If too much siliconerubber is used when sealing the cover to thecase, the excess sealant can plug the fluidfilter and cause case failure.

Coat the mating surfaces of the case and coverwith a small bead of sealant.

2006 F-150, Mark LT, 9/2005

308-07B-19 308-07B-19Transfer Case

DISASSEMBLY AND ASSEMBLY (Continued)

26. Position the 2 transfer case halves and tightenthe bolts according to sequence shown.

• Tighten to 24 Nm (18 lb-ft).

27. Install the rear output shaft snap ring. 28. Apply a small bead of sealant to the transfercase cover and extension housing mating• Lift up on the output shaft while installingsurfaces.the snap ring.

2006 F-150, Mark LT, 9/2005

308-07B-20 308-07B-20Transfer Case

DISASSEMBLY AND ASSEMBLY (Continued)

29. Install the extension housing.

1 Position the brown clutch coil wire throughits hole in the extension housing.

2 Position the extension housing.

3 Install the extension housing bolts.

X Tighten to 24 Nm (18 lb-ft).

32. Install the coil wire into the shift motorelectrical connector.

• Install the coil wire and pin.

• Install the ground wire and pin.

• Install the wire connector spacer.

30. Using the special tool, install the oil seal, ifremoved.

33. Remove the transfer case from the special tool.

31. NOTE: Tighten the 3 motor bolts first, then thebracket bolt.

Install the transfer case shift motor.

• Tighten to 10 Nm (89 lb-in).

2006 F-150, Mark LT, 9/2005

308-07B-21 308-07B-21Transfer Case

DISASSEMBLY AND ASSEMBLY (Continued)

34. Install the transfer case in the vehicle. Foradditional information, refer to Transfer Case inthis section.

2006 F-150, Mark LT, 9/2005