308-07B-1 Transfer Case — Automatic Shift 308-07B-1

DISASSEMBLY AND ASSEMBLY

Transfer Case Special Tool(s)
Installer, Needle Bearing
Special Tool(s) 308-089 (T83T-7127-A)

Adapter for (Handle) 303-224

205-153 (T80T-4000-W)

Installer, Shaft Bearing Cone

308-169 (T88T-7025-B)

Collet (1-Inch to 1-1/4-Inch)

303-D021 (D80L-100-S) or
equivalent

Installer, Transmission Output

Shaft Flange
205-495
Holding Fixture, Drive Pinion
Flange
205-126 (T78P-4851-A)

Installer, Valve Stem Oil Seal

303-367 (T90P-6510-AH)

Holding Fixture, Transmission

307-003 (T57L-500-B)

Installer, Wheel Hub Bearing

Cup
204-020 (T73T-1202-A)
Installer, Drive Pinion Oil Seal
205-304 (T90T-4676-A)

Plate, Bearing Oil Seal

205-090 (T75L-1165-B)

Installer, Input Shaft Bearing

308-085 (T83T-7025-C)

Puller, Bearing
205-D064 (D84L-1123-A) or
equivalent
(Continued)

(Continued)

Copyright  2005, Ford Motor Company

Last updated: 6/30/2005 2006 Ranger, 9/2005
308-07B-2 Transfer Case — Automatic Shift 308-07B-2
DISASSEMBLY AND ASSEMBLY (Continued)
Special Tool(s) Material
Remover, Input Shaft Bearing Item Specification
308-201 (T91T-7127-A) MERCON Multi-Purpose MERCON
ATF Transmission Fluid
XT-2-QDX
Ultra Silicone Sealant Dana 5-17
F7TZ-19554-AA

Remover, Oil Seal

303-409 (T92C-6700-CH)

Remover, Stator Bearing

307-318 (T94P-77001-KH)

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

2006 Ranger, 9/2005

308-07B-3 Transfer Case — Automatic Shift 308-07B-3
DISASSEMBLY AND ASSEMBLY (Continued)
Disassembly

Transfer Case Disassembled View

2006 Ranger, 9/2005

308-07B-4 Transfer Case — Automatic Shift 308-07B-4
DISASSEMBLY AND ASSEMBLY (Continued)
Item Part Number Description Item Part Number Description
1 7050 Front adapter assembly 39 7C430 Shift fork facing (also part of
2 7B215 Oil seal (also part of 7050) 7289)
3 — Spiral pin (part of 7050) 40 — Reduction shift fork (part of
7289)
4 — Front adapter (part of 7050)
41 7289 Lockup fork
5 7917 Snap ring (also part of 7050)
42 7219 Return spring
6 7917 Snap ring
43 7100 Shift collar hub
7 7025 Bearing
44 7917 Snap ring (also part of 7005)
8 7A385 Thrust washer
45 7025 Bearing (also part of 7005)
9 7C122 Snap ring
46 — Transfer cover assembly (part
10 7B066 Thrust plate of 7005)
11 7D063 Sun gear 47 — Identification tag
12 7017 Input shaft assembly 48 7A443 Bolt
13 — Snap ring 49 7A443 Bolt
14 7D164 Lockup hub 50 7K470 Bracket
15 7D126 Sleeve return spring 51 — Bolt
16 7106 Lockup collar 52 — J clip
17 7177 Drive sprocket 53 7045 Nut
18 7065 Sleeve bearing (also part of 54 7B368 Washer
7017)
55 7052 Oil seal
19 7120 Needle bearing (also part of
7017) 56 7B214 Flange
20 — Input shaft (part of 7017) 57 7G360 Motor assembly and
connector
21 — Pinion thrust washer (part of
7A398) 58 7B215 Oil seal
22 — Needle roller bearings (part of 59 7072 Spacer
7A398) 60 7A010 Pipe plugs
23 — Pinion needle spacer (part of 61 7B216 Oil seal (also part of 7005)
7A398) 62 — Transfer case cover (part of
24 — Pinion gear (part of 7A398) 7005)
25 7A398 Complete carrier assembly 63 — Drive chain
26 — Planet pinion pin (part of 64 7917 Snap ring
7A398) 65 7127 Needle bearing (also part of
27 — Planet carrier (part of 7A398) 7005)
28 7A443 Bolt 66 7119 Spacer
29 7034 Breather barb 67 7240 Shift rail
30 7A153 Ring gear (part of 7005) 68 — Driven sprocket
31 7100 Reduction hub 69 7F063 Electric shift cam
32 — Shaft assembly 70 7W074 Torsion spring
33 7B362 Spring pin (also part of 7005) 71 7Z112 Spacer
34 — Output shaft 72 7N095 Shift shaft
35 7A149 Pump assembly 73 — Cam pin (part of 7289)
36 — Hose clamp 74 — Cam roller (part of 7289)
37 — Hose 75 7289 Reduction fork assembly
38 7A098 Oil strainer 76 7E290 Magnet
(Continued) 77 7917 Snap ring
(Continued)

2006 Ranger, 9/2005

308-07B-5 Transfer Case — Automatic Shift 308-07B-5
DISASSEMBLY AND ASSEMBLY (Continued)
Item Part Number Description
78 7917 Snap ring (also part of 7005)
79 7025 Bearing (also part of 7005)
80 7B362 Dowel pin (also part of 7005)
81 — Transfer Case (part of 7005)
82 7005 Transfer case assembly
83 7B215 Oil seal
84 7C016 Dust deflector (also part of
7061)
85 7061 Front output shaft assembly
86 — Front output shaft (part of
7061)
4. Using a suitable puller, remove the flange.
1. Remove the transfer case from the vehicle. For
additional information, refer to Transfer Case in
this section.

2. Attach the transfer case to the special tool.

5. Remove the oil seal if it remains on the rear

output shaft.

3. CAUTION: Index-mark the rear

output shaft and the flange.
CAUTION: The nut has a self-locking
feature. Discard the nut and the washer after
removing them.
Use the special tool to prevent the flange from
turning. Remove and discard the nut and the
washer.

2006 Ranger, 9/2005

308-07B-6 Transfer Case — Automatic Shift 308-07B-6
DISASSEMBLY AND ASSEMBLY (Continued)
6. Using the special tool, remove the oil seal.

10. Remove the front bolt and the motor assembly

and connector.
7. Remove the spacer.

11. Remove the bolts that retain the transfer case

8. Remove the bolts retaining the harness to the cover to the transfer case.
motor assembly and connector.

9. Remove the rear shift motor bolt.

2006 Ranger, 9/2005

308-07B-7 Transfer Case — Automatic Shift 308-07B-7
DISASSEMBLY AND ASSEMBLY (Continued)
12. Remove the bolts that retain the transfer case to
the transfer case cover.

16. Using the special tools, remove the needle

bearing.

13. NOTE: Position the assembly so that the front

of the transfer case is facing downward.
Insert a breaker bar between the pry bosses, and
separate the transfer case cover from the
transfer case.

17. Remove the following:

1 Remove the shift collar hub.
2 Remove the return spring.
3 Remove the lockup collar and the lockup
fork as an assembly.
14. Remove the snap ring that retains the bearing in 4 Remove the electric shift cam assembly.
the case. 5 Remove the shift rail.

15. Using the special tools, remove the bearing.

2006 Ranger, 9/2005

308-07B-8 Transfer Case — Automatic Shift 308-07B-8
DISASSEMBLY AND ASSEMBLY (Continued)
18. Remove the snap ring.

22. Remove the magnet and the oil strainer from

the slot in the transfer case.
19. Remove the lockup hub and the sleeve return
spring from the lockup collar.

23. Remove the rear output shaft and the pump

assembly as an assembly.
20. Remove the snap ring and the spacer.

21. Remove the drive chain, the driven sprocket,

and the drive sprocket as an assembly.

2006 Ranger, 9/2005

308-07B-9 Transfer Case — Automatic Shift 308-07B-9
DISASSEMBLY AND ASSEMBLY (Continued)
24. Rotate the pump assembly to align the keyway
in the cover and the spring pin in the rear
output shaft, and separate the pump from the
shaft.

27. Remove the front output shaft assembly.

25. CAUTION: The height of the oil pump

spring pin must be measured before removal
so that during assembly, it can be installed at
the correct height to make sure that the oil
pump shaft rotates with the rear output
shaft.
Using a micrometer, measure and record the
pump drive pin height above the diameter of
the rear output shaft, and remove the drive pin
from the rear output shaft. 28. Remove the reduction fork assembly and the
reduction hub as an assembly.

26. CAUTION: Do not let the front output

shaft assembly fall out of the case while
removing the snap ring.
Remove the snap ring. Discard the snap ring if
deformed during removal.

2006 Ranger, 9/2005

308-07B-10 Transfer Case — Automatic Shift 308-07B-10
DISASSEMBLY AND ASSEMBLY (Continued)
29. Remove the 6 bolts retaining the front adapter 32. Remove the large snap ring from the front
assembly to the case. adapter.

30. Remove the front adapter assembly, the input 33. Using a suitable tool, remove the oil seal from
shaft assembly, and the complete carrier the front adapter.
assembly as an assembly.

34. Remove the snap ring.

31. Using snap ring pliers, expand the tangs of the
large snap ring and remove the complete carrier
assembly and the input shaft assembly from the
front adapter.

2006 Ranger, 9/2005

308-07B-11 Transfer Case — Automatic Shift 308-07B-11
DISASSEMBLY AND ASSEMBLY (Continued)
35. Using the special tool and a suitable press, 38. NOTE: Remove and discard both the sleeve
remove the bearing. bearing and the needle bearing if either one is
worn/damaged.
Using the special tools and a suitable press,
remove the needle bearing and the sleeve
bearing from the input shaft.

36. Remove the thrust washer and the input shaft

assembly.

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

37. Remove the snap ring, the thrust plate, and the
sun gear.

40. Remove the snap ring retaining the bearing to

the case.

2006 Ranger, 9/2005

308-07B-12 Transfer Case — Automatic Shift 308-07B-12
DISASSEMBLY AND ASSEMBLY (Continued)
41. Using the special tools, remove the bearing.

45. WARNING: Keep fingers away from

spring ends. Failure to follow these
42. Using a suitable tool, remove the oil seal. instructions can result in personal injury.
Remove the torsion spring and the spacer from
the shift shaft.

43. Remove the shift fork facings.

Assembly

NOTE: Prior to assembly, lubricate all parts with

multi-purpose transmission fluid.

1. Using the special tools and a suitable press,

install the bearing.

44. Remove the electric shift cam from the shift

shaft.

2006 Ranger, 9/2005

308-07B-13 Transfer Case — Automatic Shift 308-07B-13
DISASSEMBLY AND ASSEMBLY (Continued)
2. Install the snap ring. 5. Using the special tools and a suitable press,
install the sleeve bearing.

6. NOTE: The recessed face of the sun gear must

face the rear of the transfer case.
Install the sun gear, the thrust plate, and the
snap ring.

3. Using the special tool, install the oil seal.

7. NOTE: The stepped face of the thrust washer

must face upward.
Install the input shaft assembly and the thrust
washer.

4. CAUTION: Do not crush the needle

bearing.
Using the special tools and a suitable press,
install the needle bearing.

8. NOTE: Install the bearing on the input shaft

assembly so that the snap ring groove in the
bearing is closest to the top of the planet
carrier.
Using a suitable press, install the bearing.

2006 Ranger, 9/2005

308-07B-14 Transfer Case — Automatic Shift 308-07B-14
DISASSEMBLY AND ASSEMBLY (Continued)
9. Install the snap ring. 12. CAUTION: Install the front adapter
within 15 minutes of applying the silicone
sealant or it will be necessary to apply new
sealant. If possible, allow one hour before
filling the transfer case with lubricant to
allow the silicone sealant to cure.
Apply a 3 mm (1/8 inch) bead of silicone
sealant to the front adapter mounting surface of
the transfer case.

10. Using the special tool, install the oil seal.

13. Position the front adapter on the transfer case,

and install the 6 bolts.
• Tighten to 34 Nm (25 lb-ft).

11. Install the large snap ring in the groove in the

front adapter.

2006 Ranger, 9/2005

308-07B-15 Transfer Case — Automatic Shift 308-07B-15
DISASSEMBLY AND ASSEMBLY (Continued)
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.

17. Install the reduction hub and the reduction fork

assembly as an assembly.

15. Attach the front case to the special tool.

18. CAUTION: The oil pump spring pin

must be installed at the correct height to
make sure that the oil pump shaft rotates
with the rear output shaft.
NOTE: If a measurement was not taken during
disassembly, install the pin to the correct height
specification using a micrometer.
Press the pin into the rear output shaft pin hole
to the previously measured height.
16. Install the new shift fork facings. Verify that
they snap securely into place.

2006 Ranger, 9/2005

308-07B-16 Transfer Case — Automatic Shift 308-07B-16
DISASSEMBLY AND ASSEMBLY (Continued)
19. NOTE: Do not remove the plastic insert from 22. Install the rear output shaft and the pump
the bore of a new pump assembly. Discard it assembly.
after it slides out of the bore during the pump
assembly installation on the rear output shaft.
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.

23. Install the oil strainer and the magnet in the slot
in the case.

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.

24. Install the front output shaft assembly.

21. Prime the pump assembly.

• Submerge the pump in a container full of
clean multi-purpose transmission fluid.

2006 Ranger, 9/2005

308-07B-17 Transfer Case — Automatic Shift 308-07B-17
DISASSEMBLY AND ASSEMBLY (Continued)
25. Install the snap ring.

28. Install the shift rail through the reduction shift

fork. Verify that the shift rail seats in the case
26. Install the drive chain, the drive sprocket and bore.
the driven sprocket as an assembly.

29. Slide the spacer and the torsion spring on the

shift shaft and position it beneath the drive
tang.

27. Install the spacer and the snap ring.

2006 Ranger, 9/2005

308-07B-18 Transfer Case — Automatic Shift 308-07B-18
DISASSEMBLY AND ASSEMBLY (Continued)
30. WARNING: Keep fingers away from
spring ends. Failure to follow these
instructions can result in personal injury.
Position the first spring tang to the left of the
drive tang.

33. CAUTION: Do not bend the cam

during installation. This will damage the pin
on the end of the shift shaft.
Install the pin on the end of the shift shaft into
the hole in the case.

31. WARNING: Keep fingers away from

spring ends. Failure to follow these
instructions can result in personal injury.
Wind the second spring tang clockwise past the
drive tang, and push the torsion spring and
sleeve in as far as it will go.

34. Position the torsion spring tangs so that they

point toward the top side of the case and just
touch the reduction shift fork.

32. Install the electric shift cam, and slide the drive
tang between the torsion spring tangs as far as
it will go.

2006 Ranger, 9/2005

308-07B-19 Transfer Case — Automatic Shift 308-07B-19
DISASSEMBLY AND ASSEMBLY (Continued)
35. Assemble the lockup assembly. 38. NOTE: After the lockup fork is released, verify
that the cam roller is resting on the top surface
of the electric shift cam and not into an inside
track.
The triangular shaft will be in the 2-wheel high
(2H) position at final assembly.

36. Press downward on the lockup hub and install

the snap ring.

39. Lift upward on the lockup fork slightly while

holding down on the shift rail and rotate the
electric shift cam track into the cam roller by
turning the shift shaft.

37. Install the lockup fork and the lockup collar as

an assembly.

40. Install the shift collar hub and the return spring.

2006 Ranger, 9/2005

308-07B-20 Transfer Case — Automatic Shift 308-07B-20
DISASSEMBLY AND ASSEMBLY (Continued)
41. CAUTION: Do not crush the needle 44. Using the special tool, install the oil seal.
bearing.
Using the special tools and a suitable press,
install the needle bearing.

45. CAUTION: Assemble the cases within

15 minutes of applying the silicone sealant or
it will be necessary to apply new sealant. If
42. Using the special tools and a suitable press, possible, allow one hour before filling the
install the bearing. transfer case with lubricant to allow the
silicone sealant to cure.
Apply a 3 mm (1/8 in) bead of silicone sealant
to the mating surface of the front case.

46. Assemble the cases.

• Align the output shaft, the shift shaft, and
the return spring to their respective bores in
the transfer case cover.

43. Install the snap ring that retains the bearing to

the transfer case cover.

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308-07B-21 Transfer Case — Automatic Shift 308-07B-21
DISASSEMBLY AND ASSEMBLY (Continued)
47. Install the bolts.
• Tighten to 34 Nm (25 lb-ft).

51. CAUTION: Align the index marks.

NOTE: Be sure the oil seal is not on the shaft
before installing the shaft.
48. Install the bolts.
Position the flange on the rear output shaft. If
• Tighten to 34 Nm (25 lb-ft). necessary, reseat the oil seal in the flange.

49. Install the spacer on the rear output shaft. 52. Install a new oil seal in the flange.

53. Using the special tool, install the flange.

Tighten the nut on the special tool to 54 Nm
(40 lb-ft) to seat the flange on the shaft.

50. Using the special tool, install the oil seal.

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308-07B-22 Transfer Case — Automatic Shift 308-07B-22
DISASSEMBLY AND ASSEMBLY (Continued)
54. Use the special tool to prevent the flange from 56. CAUTION: Install the motor assembly
turning. Install a new washer and a new nut. within 15 minutes of applying the silicone
• Tighten to 210 Nm (155 lb-ft). sealant or it will be necessary to apply new
sealant. If possible, allow one hour before
filling the transfer case with lubricant to
allow the silicone sealant to cure.
Apply a thin coat of silicone sealant to the base
of the motor housing.

57. Install the motor assembly and connector.

• Tighten to 10 Nm (89 lb-in).

55. If the shift shaft will not stay in the 4H

position, rotate the shift shaft clockwise to the
2H position. During motor assembly and
connector installation, rotate the motor assembly
counterclockwise until the motor assembly
aligns with the mounting holes.

58. Install the transfer case. For additional

information, refer to Transfer Case in this
section.

2006 Ranger, 9/2005