1998 F -150/250 Workshop Manual Page 1 of 23

Transfer Case

SECTION 308-07B: Transfer Case 1998 F-150/250 Workshop Manual DISASSEMBLY AND ASSEMBLY Procedure revision date: 03/07/2000

Special Tool(s)

Actuator Pin 303-D012 (D80L-100-H) or Equivalent

Bearing Cup Remover 308-047 (T77F-1102-A)

Bearing Cup Replacer 204-020 (T73T-1202-A)

Bench Mounted Holding Fixture 307-003 (T57L-500-B)

Blind Hole Puller Set 303-DS005 (D80L-100-A)

Center Bearing Replacer 308-060 (T77J-7025-K)

Collet (1-Inch to 1-1/4-Inch) 303-D021 (D80L-100-S) or Equivalent

Collet (1-1/4-Inch to 1-1/2-Inch) 303-D022 (D80L-100-T) or Equivalent

Driver Handle 205-153 (T80T-4000-W)

Dust Shield Replacer 205-274 (T88C-5493-CH)

Extension Housing Seal Replacer 308-002 (T61L-7657-A)

Input Shaft Bearing Replacer 308-085 (T83T-7025-C)

Seal Protector 308-251 (T96T-7127-C)

Page 1 of 231998 F-150/250 Workshop Manual

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Disassembly

Transfer Case Exploded View — Manual Shift

Seal Remover 303-409 (T92C-6700-CH)

Seal Replacer 308-249 (T96T-7127-A)

Seal Replacer 308-250 (T96T-7127-B)

Slide Hammer 100-001 (T50T-100-A)

Slide Hammer 303-D008 (D80L-100-D) or Equivalent

Valve Stem Seal Replacer 303-367 (T90P-6510-AH)





Item Part Number Description

1 7917 Snap Ring

2 7A153 Ring Gear

3 7064 Snap Ring

4 7A398 Front Planet

5 7120 Needle Bearing

6 7065 Bushing

7 7A149 Pump Assy

8 7177 Drive Sprocket

9 7106 Lockup Collar

10 7D126 Spring

11 7D164 Output Shaft Hub

12 9324 Hose Clamp (Cut from Fuel Tube Hose)

13 — Hose

14 7A098 Lube Pickup and Filter

15 7C349 Detent Spring

16 7C191 Detent Roller

17 7B106 Shift Lever Assy

18 7E182 Shift Shaft Oil Seal

19 7A443 Bolt

20 7F063 Mechanical Shift Cam

21 7177 Driven Sprocket

22 7A029 Drive Chain Assy

23 7917 Snap Ring

24 7025 Bearing

25 7E290 Magnet

26 — Dowel (Part of 7005)

27 7C207 Case Stud

28 7B215 Yoke to Flange Seal

29 7C016 Shield



Transfer Case Exploded View — Electric Shift

30 7061 Front Output Shaft with Shield

31 7E440 Three-Position Switch

32 7034 Breather Barb


34 7005 Case

35 7N281 Input Snap Ring

36 7025 Bearing

37 7061 Output Shaft

38 7100 Reduction Hub

39 7F135 Spring

40 7H150 Armature

41 7917 Snap Ring

42 7G362 Hub and Coil Housing Assy

43 7917 Snap Ring

44 7G361 Coil

45 7025 Bearing

46 7917 Snap Ring

47 7005 Case

48 7A443 Bolt

49 NG20480-52 Nut

50 7A010 Case Plug

51 — Bar Code Label (Part of 7005)

52 7025 Bearing

53 7N063 Spacer

54 7A443 Bolt


56 7C207 Case Stud

57 17264 Speedometer Isolator Plate

58 — Wire Convolute (Part of 7005)

59 — Connector Harness (Part of 7005)

60 — Wire Connector Spacer (Part of 7005)

61 — Harness Connector Retainer (Part of 7005)

62 — Identification Tag (Part of 7005)

63 17291 Speedometer Gear Spacer

64 17285 Speedometer Drive Gear

65 353351-S Ball

66 7085 Extension Housing Assy

67 7219 Lockup Fork Spring

68 7240 Shift Rail

69 7289 Lockup Fork

70 7289 Reduction Shift Fork Assy

71 7C430 Shift Fork Pad





Item Part Number Description

1 7917 Snap Ring

2 7A153 Ring Gear

3 7064 Snap Ring

4 7A398 Front Planet

5 7120 Needle Bearing

6 7065 Bushing

7 7100 Reduction Hub

8 7A149 Pump Assy

9 7177 Drive Sprocket

10 7106 Lockup Collar

11 7D126 Spring

12 7D164 Lockup Hub

13 — Hose Clamp (Part of 7A149)

14 9324 Hose (Cut from Fuel Tube Hose)

15 7A098 Lube Pickup and Filter

16 7E290 Magnet

17 7025 Bearing

18 7917 Snap Ring

19 7177 Driven Sprocket

20 7A029 Drive Chain Assy

21 — Dowel (Part of 7005)

22 7C207 Case Stud


24 7C016 Shield

25 7061 Front Output Shaft with Shield

26 7034 Breather Barb


28 7005 Case

29 7N281 Input Snap Ring



NOTE: On the manual shift transfer case, place the transfer case (7A195) in the neutral position for disassembly.

1. Remove the transfer case. � Refer to Transfer Case, Removal in this section.

2. On manual shift transfer case, remove the 4WD indicator switch.

3. Secure the transfer case. � Use the Bench Mounted Holding Fixture.

30 7025 Bearing

31 7061 Output Shaft

32 7F135 Spring

33 7H150 Armature

34 7917 Snap Ring

35 7G362 Hub and Coil Housing

36 7917 Snap Ring

37 7G361 Coil

38 7025 Bearing

39 7917 Snap Ring

40 7005 Case

41 7A443 Bolt

42 N62048C-S2 Nut

43 7A010 Case Plug

44 7G360 Transfer Case Shift Motor

45 — J-Clip (Part of 7G360)

46 N800670-S Bolt

47 — Wire Connector Spacer (Part of 7G360)

48 7A443 Bolt

49 7288 Shifter Shaft Seal

50 — Bar Code Label (Part of 7005)

51 7A010 Case Plug

52 7025 Bearing

53 7N063 Spacer

54 7A443 Bolt


56 7C207 Case Stud

57 17264 Speedometer Isolator Plate

58 — Wire Convolute (Part of 7085)

59 — Identification Tag (Part of 7085)

60 17291 Speedometer Gear Spacer

61 17285 Speedometer Drive Gear

62 353315-S Ball

63 7085 Extension Housing

64 7F063 Shift Shaft

65 7240 Shift Rail

66 7219 Lockup Fork Spring

67 7289 Lockup Fork

68 7289 Reduction Shift Fork Assy

69 7C430 Shift Fork Pad



4. Remove the coil wire from the electric shift motor electrical connector. 1. Remove the wire connector spacer. 2. Remove the coil wire and pin.

� Use an electrical connector pin extractor tool.

5. Remove the vehicle speed sensor (VSS) (9E731). 1. Remove the VSS bolt. 2. Remove the VSS.

6. On electrical shift transfer case, remove the transfer case shift motor (7G360). 1. Remove the bolts. 2. Remove the transfer case shift motor.

7. Remove the extension housing. 1. Remove the six extension housing bolts. 2. Remove the extension housing.

8. Remove the speedometer gear spacer. 1. Remove the speedometer gear spacer. 2. Push the speedometer drive gear (17285) toward the transfer case.



9. Remove the speedometer drive gear. 1. Remove the steel ball. 2. Remove the speedometer drive gear.

10. Remove the rear output shaft snap ring (7917). � Lift up on the output shaft while removing the snap ring.

11. NOTE: The transfer case bolts (7A443) are self-tapping, and it is normal to find metal shavings while removing the cover.

Remove the transfer case bolts.

12. Remove the transfer case cover. � Use pry bosses to separate the cover from the case.

13. Remove the coil. 1. Remove the three coil to cover nuts. 2. Remove the coil.



14. Remove the front output shaft bearing. � Use the Slide Hammer and Bearing Cup Remover.

15. Remove the rear output shaft bearing. � Use the Slide Hammer and the Bearing Cup Remover.

16. Remove the shift collar hub. � Remove the shift collar hub snap ring from the rear output shaft.

17. Remove the coil housing.

18. Remove the shift fork. 1. Remove the lockup hub. 2. Remove the shift fork and spring.

19. NOTE: Remove the lockup hub assembly as a single unit. If disassembly is required, proceed with the following.

Disassemble the lockup hub assembly. 1. Remove the lockup hub snap ring. 2. Separate the lockup collar. 3. Separate the two lockup springs.



4. Separate the lockup hub. 5. Remove the armature.

20. Remove the spacer.

21. Remove drive chain and sprocket assembly.

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

23. NOTE: The pump assembly is not repairable.

Remove the oil pump and the output shaft as an assembly. � Remove the oil pump from the output shaft.

24. Remove the shift fork shaft.



25. Remove the shift fork and the reduction hub. 1. Remove the shift fork. 2. Remove the reduction hub.

26. WARNING: Do not disassemble shift cam assembly.

On electrical shift transfer case, remove the electric shift cam assembly.

27. Use the Seal Remover to remove the input seal.

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

Remove the front planet carrier. 1. Remove the front planet carrier snap ring. 2. Remove the front planet carrier.

29. Remove the ring gear. 1. Remove the ring gear snap ring. 2. Remove the ring gear.



30. CAUTION: Do not let the front output shaft fall wh ile 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 front yoke to flange seal (7B215). � Use the Bearing Cup Remover and the Slide Hammer.

32. If necessary, remove the bushing and needle bearing from the front planet carrier. � Use 1.25 - 1.50-inch collet, actuator pin and slide hammer from Blind Hole Puller Set for bushing. � Use 1 - 1.25-inch collet, actuator pin and slide hammer from Blind Hole Puller Set for bearing.

33. Remove the front planet carrier bearing snap ring.

34. Remove the front planet carrier bearing. � Use the Bearing Cup Replacer and the Driver Handle.



35. Remove the front output shaft bearing. � Use the Bearing Cup Remover and the Slide Hammer.

36. NOTE: On manual shift transfer case, access the shift lever set screw through the 4WD indicator switch hole.

Loosen the shift lever set screw.

37. On manual shift transfer case, remove the shift lever (from outside of case), shift cam and spring.

38. On manual shift transfer case, remove the shift lever seal. � Use the collet and the slide hammer from the Blind Hole Puller Set.

39. On electrical shift transfer case, remove the electric shift motor seal. � Use the collet and the slide hammer from the Blind Hole Puller Set.



Assembly

1. On electrical shift transfer case, install the electric shift motor seal. � Use the Seal Replacer.

2. On manual shift transfer case, install the shift lever seal. � Use the Seal Replacer.

3. On the manual shift transfer case, install the shift lever (from outside of case), shift cam and spring.

4. NOTE: On manual shift transfer case, access the shift lever set screw through the 4WD indicator switch hole.

Tighten the shift lever set screw.

5. Install the front output shaft bearing. � Use the Driver Handle and the Bearing Replacer.



6. Install the front planet carrier bearing. 1. Install the front planet carrier bearing.

� Use the Dust Shield Replacer and the Driver Handle. 2. Install the front planet carrier bearing snap ring.

7. If removed, install the bushing and needle bearing into the front planet carrier. � Use the Input Shaft Bearing Replacer.

8. Install the front yoke to flange seal. � Use the Seal Replacer.

9. Install the front output shaft. 1. Position the front output shaft. 2. Install the front output shaft snap ring.

10. Install the ring gear. 1. Position the ring gear. 2. Install the ring gear snap ring.



11. Install the front planet carrier. 1. Position the front planet carrier. 2. Install the front planet carrier snap ring.

12. Install the input seal. � Use the Seal Replacer and the Seal Protector.

13. On electrical shift transfer case, install the electric shift cam assembly.

14. Install the shift fork and the reduction hub.

15. Install the shift fork shaft.



16. Install the oil pump onto the output shaft.

17. Install the oil pump and the output shaft.

18. Install the magnet into its slot in the case (7005).

19. Install the drive chain and sprocket assembly.

20. Install the spacer.

21. NOTE: If the lockup hub assembly was disassembled, perform 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.



22. Install the lockup hub and the shift fork and spring.

23. Install the coil housing.

24. Install the shift collar hub. � Install the shift collar hub snap ring onto the rear output shaft.

25. Install the rear output shaft bearing. � Use the Center Bearing Replacer and the Driver Handle.

26. Install the front output shaft bearing. � Use the Center Bearing Replacer and the Driver Handle.

27. Install the coil. 1. Position the coil. 2. Install the nuts.



28. CAUTION: If too much silicone rubber is used when sealing the cover to case, the excess sealant may p lug the fluid filter and cause case failure.

Coat the mating surfaces of the case and cover with a small bead of sealant. � Use Black Non-Acid Cure Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M4G273-A.

29. Position the two transfer case halves and tighten the bolts according to sequence.

30. Install the rear output shaft snap ring. � Lift up on the output shaft while installing the snap ring.

31. Install the speedometer drive gear and steel ball. 1. Slide the speedometer gear onto the output shaft until it touches the case. 2. Position the steel ball.

32. Install the speedometer gear spacer. 1. Lift up on the speedometer gear. 2. Install the speedometer gear spacer.



33. Apply a small bead of sealant to the transfer case cover and extension housing mating surfaces. � Use Black Non Acid Cure Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M4G273-A.

34. Install the extension housing. 1. Position the brown clutch coil wire through its hole in the extension housing. 2. Position the extension housing. 3. Install the extension housing bolts.

35. Install the vehicle speed sensor. 1. Position the VSS. 2. Install the VSS bolt.

36. On electrical shift transfer case, install the transfer case shift motor. 1. Position transfer case shift motor. 2. Install the bolts.

37. Install the coil wire into the shift motor electrical connector. 1. Install the coil wire and pin. 2. Install the wire connector spacer.



38. Remove the transfer case from the bench holding fixture.

39. On manual shift transfer case, install the 4WD indicator switch.

40. Install the transfer case in the vehicle. � Refer to Transfer Case, Installation in this section.



Documents

1998 F -150/250 Workshop Manual Page 1 of 23