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bw1356manex.jpg BW1356 Exploded, manual shift, early (rear yoke)
IF THE IMAGE IS TOO SMALL, click it.

See also:
[url=https://www.supermotors.net/registry/media/937270][img]https://www.supermotors.net/getfile/937270/thumbnail/pump01.jpg[/img][/url] . [url=https://www.supermotors.net/registry/media/425678][img]https://www.supermotors.net/getfile/425678/thumbnail/tcase.jpg[/img][/url]

The range switch 7B440 might be Ford 4L3Z7E440AB/ MC SW6251 (OEM: Pollack).

Transfer Case, Mechanical Shift

SPECIAL SERVICE TOOL(S) REQUIRED
Description Tool Number
Impact Slide Hammer T50T-100-A
Bearing Cup Replacer T73T-1202-A
Driver Handle T80T-4000-W
Bearing Cup Replacer T73T-1202-B
Bearing Cup Replacer T80T-4000-P
Output Shaft Seal Replacer T86T-7034-CH
Extension Housing Seal Replacer T61L-7657-B


Disassembly

1. Remove transfer case (7A195) from vehicle. Refer to Transfer Case procedure in the Removal and Installation portion of this section.
2. Remove front shaft nut (7045), output shaft yoke washer (7B368 ), and oil seal (7052) and remove the front output case yoke (7B214) from the transfer case. On Bronco, repeat procedure for rear output circular case yoke.
3. Remove the 4WD indicator switch and aluminum spacer washer from the transfer case. Do not lose this washer as it is required for the proper operation of this switch.
4. Remove the front and rear output shaft yoke to flange seals (7B215) using a screwdriver.
5. Remove the input shaft yoke to flange seal using screwdriver.
6. Remove the four No. 50 Torx%uFFFD head bolts (7A443) securing the rear bearing retainer to the case. Pry the rear bearing retainer from the rear case using a 1/2-inch drive breaker bar between the pry bosses and separate and remove the rear bearing retainer from the case. Remove all traces of silicone rubber from the mating surfaces of the case and the bearing retainer. CAUTION: When removing RTV sealant, use care not to damage the mating surfaces of the magnesium cases (7005).
7. Remove the snap ring on the rear output shaft retaining the upper rear bearing (7025) using snap ring pliers.
8. Remove the 12 No. 50 Torx%uFFFD head bolts that retain the front case to the rear case. Insert a 1/2-inch drive breaker bar between the pry bosses and separate. Lift the front case from the rear case. Remove all traces of RTV Gasket Sealant from the mating surfaces of the front case and the rear case. CAUTION: When removing the silicone rubber, use care not to damage the mating surfaces of the magnesium cases.
9. Remove front output shaft caged needle bearing from the rear case with Impact Slide Hammer T50T-100-A and Collet D80L-100-T from Blind Hole Puller Set D80L-100-A or equivalent.
10. Drive out the rear output shaft bearing from the inside of the rear case using a brass drift, tapping it lightly with a small hammer so as not to cause any damage to the case.
11. Remove the snap ring from the output shaft securing the shift collar hub. Slide the shift collar hub off of the output shaft.
12. Remove the shift fork spring from the shift rail and lift the shift mode (2WD/4WD) fork complete with the shift collar hub from the rear output shaft.
13. Disassemble the 2W-4W lockup assembly by removing the internal snap ring and pull the lockup hub and spring from the lockup collar.
14. Remove the snap ring retaining the driven sprocket to the front output shaft. Grasp the drive and driven sprocket complete with the chain and lift them at the same time from the drive and driven output shafts.
15. Remove the shift rail by sliding it straight out from the shift fork.
16. Lift out the pump screen and remove the output shaft with the pump assembled on it. If the pump is to be disassembled, remove the four bolts from the pump body. Note the position of the pump front body, pins, spring, rear cover and pump retainer as removed. CAUTION: Do not disassemble oil pump unless the oil pump retaining bracket has been bent or broken, or pump damage is indicated. Indications of pump damage are blueing or blackening of the pump, or loosening of the pump bolts.
17. Remove the oil pan magnet (7L027) from its slot in the case.
18. Remove the high-low shift fork by first rotating it until the roller is free from the cam, then sliding out of engagement from the shift collar hub.
19. Remove the shift collar hub.
20. Turn the front case over and remove the front input yoke to flange seal from the case using a screwdriver.
21. Reaching through the front opening with a pair of snap ring pliers, carefully expand the snap ring on the input shaft allowing it to drop out of the bearing. The front planet (7A398 ), including the input shaft, is serviced as an assembly only. If the bearing or bushing is to be replaced, drive out both of them through the input spline using suitable tools such as a brass drift and a small hammer, being careful not to damage the case.
22. Remove the ring gear (7A153) by prying out the internal snap ring with a screwdriver and lift out the gear.
23. Remove the internal snap ring securing the input shaft bearing to the case.
24. Remove the input shaft bearing using Bearing Cup Replacer T73T-1202-A and Driver Handle T80T-4000-W.
25. Remove the internal snap ring securing the front output shaft bearing in the case.
26. Drive the bearing out from the front of the case using Bearing Cup Replacer T73T-1202-B and Driver Handle T80T-4000-W.
27. Place the shift lever in the NEUTRAL position so the shift cam setscrew can be seen through the hole for the 4WD indicator switch.
28. Remove the setscrew using a hex key tool.
29. Remove the shift lever by sliding it out of the case.
30. Remove the shift cam.
31. Remove the shifter shaft seal (7288 ) by carefully prying it out of the case, being careful not to damage the case.
32. Remove the shift cam, assist spring, and assist spring bushing from the case.

Assembly
Before assembly, lubricate all parts with Motorcraft MERCON%uFFFD ATF XT- 2-QDX or MERCON%uFFFD equivalent. Remove all chips from the bolt holes in the case and rear case.

1. Install the input shaft and the front output shaft bearing in the case using Bearing Cup Replacer T80T-4000-P and Driver Handle T80T-4000-W. Install the internal snap rings retaining the bearing in the case.
2. Drive the front output yoke to flange seal into the case until it is fully seated against the case using Output Shaft Seal Replacer T86T-7034-CH.
3. Install the front output shaft through the lower bearing. The front output shaft is held in place in the case by the front output yoke to flange seal and oil seal slinger. Install the front case yoke onto the front output shaft, then the oil seal, output shaft yoke washer and 32mm shaft nut. Tighten the yoke shaft nut to 203-244 Nm (150-180 lb-ft).
4. Press the needle bearing and bronze bushing into the input shaft and carrier assembly with the appropriate tools, making sure that the bearing and bushing are driven in straight.
5. Install the ring gear into the slots in the case and retain it with the large internal snap rings making sure that it is fully seated.
6. Install the input shaft and front planet in the case through the input shaft bearing, being careful not to damage the gear teeth when aligning them with the ring gear teeth.
7. While supporting the front planet in position, install a new snap ring on the front side of the input shaft bearing, making sure that it is fully seated in the snap ring groove of the input shaft.
8. Install the upper input shaft yoke to flange seal into the case using an appropriate tool until it is fully seated against the case.
9. Install a new shifter shaft seal into the case using an appropriate tool.
10. Install the shift cam detent spring in position in the bushing of the shift cam and in the recess in the case.
11. Assemble the shift cam into the case by sliding the shift shaft and lever through the case and seal into engagement with the shift cam. Install the setscrew through the holes in the case for the 4WD indicator switch.
12. Lubricate all pump parts with clean automatic transmission fluid prior to assembly.
13. Assemble the pump and output shaft as follows:
- a. Place the oil pump cover with the word TOP facing the front of the case.
- b. Install the two pins (with the flats facing toward the rear of the vehicle) with the spring between the pins and place the assembly in the oil pump bore in the output shaft.
- c. Place the oil pump body and pick-up tube over the output shaft and make sure that the pins are riding against the inside of the pump body.
- d. Place the oil pump rear cover with the words TOP REAR facing the rear of the output shaft. NOTE: The word TOP on the front cover and the rear cover should be on the same side.
- e. Install the pump retainer with the tabs facing the front of the transfer case.
- f. Install the four retaining bolts and rotate the output shaft while tightening the bolts to prevent the pump from binding. Tighten bolts to 4-4.5 Nm (36-40 lb-in). NOTE: The output shaft must turn freely within the oil pump. If binding occurs, loosen the four bolts and retighten as outlined.
14. Install the shift collar. Install the high-low shift fork by engaging it with the shift hub flange and rotating it until the roller is engaged with the lower groove of the cam.
15. Install the shift rail through the high-low fork bore and into the rail bore in the case.
16. Install the output shaft and oil pump in the input shaft. Make sure the external splines of the output shaft engage the internal splines of the shift collar hub. Make sure the oil pump retainer and oil filter leg are in the groove and notch of the front case. Install the oil pan magnet in the slot in the front case.
17. Assemble the following components:
- a. Assemble the drive sprocket into the chain.
- b. Assemble the driven sprocket into the chain so the word REAR is facing upward. NOTE: The sprocket engagement spline will face the rear of the vehicle when properly installed.
- c. Place the sprockets and chain as an assembly over the rear and front output shafts.
- d. Install the thrust washer (7119) and snap ring that retains the lower sprocket to the front output shaft.
18. Assemble the 2W-4W lockup as follows:
- a. Position the small end of the tapered compression spring in the lockup collar.
- b. Place the lockup hub over the large end of the spring and compress the spring while installing the internal snap ring. NOTE: The snap ring holds the lockup together.
19. Install the lockup and its shift fork over the external splines of the drive sprocket and the shift rail with the cam follower feature of the fork facing the front of the transfer case.
20. Assemble the 4WD return spring over the shift rail and against the shift fork.
21. Place the lockup hub over the external splines of the output shaft and secure with the appropriate snap ring. Make sure the snap ring is fully seated in the snap ring groove.
22. Press the front output needle bearing in its bore in the rear case using an appropriate tool.
23. Press the rear output shaft bearing into position in the rear case using an appropriate tool. Install bearing snap ring retainer in rear case.
24. Install the rear output shaft yoke to flange seal in the bearing retainer using the appropriate tool and making sure that it is fully seated.
25. Coat the mating surface of the front case with a very small bead of Black Non-Acid Cure Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M4G273-A. CAUTION: If too much silicone rubber is used when sealing the case halves, the excess sealant may plug the oil filter and cause case failure.
26. Place the case halves together making sure that the front output shaft, shift shaft and shift rail are aligned. Install and tighten the 12 No. 50-Torx%uFFFD head bolts to 35-43 Nm (26-32 lb-ft).
27. Install the rear bearing snap ring on the output shaft making sure that the snap ring is fully seated in the groove of the output shaft.
28. Apply a very small bead of Black Non-Acid Cure Silicone Rubber ET7Z-19562-A or equivalent meeting Ford specification ESL-M4G273-A to the face of the rear bearing retainer or rear slip-yoke extension housing (7A039).
29. Place the rear bearing retainer or rear slip-yoke extension housing in its position and secure with the four Torx%uFFFD bolts tightened to 30-49 Nm (22-36 lb-ft).
30. On transfer case with slip-yoke rear bearing retainer housing, remove the yoke to flange seal using a screwdriver. If the bushing in the rear slip yoke extension housing is damaged and must be replaced, it must be replaced with the extension housing as an assembly. The bushing alone cannot be serviced. Install a new seal using Extension Housing Seal Replacer T61L-7657-B.
31. For fixed yoke models, install the rear output shaft case yoke and slinger onto the rear splines of the output shaft. Install the oil seal, output shaft yoke washer and 32mm shaft nut on the output shaft and tighten to 163-203 Nm (120-150 lb-ft).
32. Install the drain plug and tighten to 9-23 Nm (7-17 lb-ft).
33. Install the 4WD indicator switch with aluminum washer into the case. Tighten 4WD indicator switch to 34-47 Nm (25-35 lb-ft).
34. Install the transfer case.
35. Fill transfer case.
36. Start engine, check transfer case for correct operation. Stop engine and check fluid level. Fluid should drip out of level hole. If fluid flows out of level hole, the oil pump may not be functioning properly.
bw1356manex.jpg | Hits: 3790 | Posted on: 12/24/16 | View original size (821.95 KB)

BW1356 Exploded, manual shift, early (rear yoke)
IF THE IMAGE IS TOO SMALL, click it.

See also:
.

The range switch 7B440 might be Ford 4L3Z7E440AB/ MC SW6251 (OEM: Pollack).

Transfer Case, Mechanical Shift

SPECIAL SERVICE TOOL(S) REQUIRED
Description Tool Number
Impact Slide Hammer T50T-100-A
Bearing Cup Replacer T73T-1202-A
Driver Handle T80T-4000-W
Bearing Cup Replacer T73T-1202-B
Bearing Cup Replacer T80T-4000-P
Output Shaft Seal Replacer T86T-7034-CH
Extension Housing Seal Replacer T61L-7657-B


Disassembly

1. Remove transfer case (7A195) from vehicle. Refer to Transfer Case procedure in the Removal and Installation portion of this section.
2. Remove front shaft nut (7045), output shaft yoke washer (7B368 ), and oil seal (7052) and remove the front output case yoke (7B214) from the transfer case. On Bronco, repeat procedure for rear output circular case yoke.
3. Remove the 4WD indicator switch and aluminum spacer washer from the transfer case. Do not lose this washer as it is required for the proper operation of this switch.
4. Remove the front and rear output shaft yoke to flange seals (7B215) using a screwdriver.
5. Remove the input shaft yoke to flange seal using screwdriver.
6. Remove the four No. 50 Torx%uFFFD head bolts (7A443) securing the rear bearing retainer to the case. Pry the rear bearing retainer from the rear case using a 1/2-inch drive breaker bar between the pry bosses and separate and remove the rear bearing retainer from the case. Remove all traces of silicone rubber from the mating surfaces of the case and the bearing retainer. CAUTION: When removing RTV sealant, use care not to damage the mating surfaces of the magnesium cases (7005).
7. Remove the snap ring on the rear output shaft retaining the upper rear bearing (7025) using snap ring pliers.
8. Remove the 12 No. 50 Torx%uFFFD head bolts that retain the front case to the rear case. Insert a 1/2-inch drive breaker bar between the pry bosses and separate. Lift the front case from the rear case. Remove all traces of RTV Gasket Sealant from the mating surfaces of the front case and the rear case. CAUTION: When removing the silicone rubber, use care not to damage the mating surfaces of the magnesium cases.
9. Remove front output shaft caged needle bearing from the rear case with Impact Slide Hammer T50T-100-A and Collet D80L-100-T from Blind Hole Puller Set D80L-100-A or equivalent.
10. Drive out the rear output shaft bearing from the inside of the rear case using a brass drift, tapping it lightly with a small hammer so as not to cause any damage to the case.
11. Remove the snap ring from the output shaft securing the shift collar hub. Slide the shift collar hub off of the output shaft.
12. Remove the shift fork spring from the shift rail and lift the shift mode (2WD/4WD) fork complete with the shift collar hub from the rear output shaft.
13. Disassemble the 2W-4W lockup assembly by removing the internal snap ring and pull the lockup hub and spring from the lockup collar.
14. Remove the snap ring retaining the driven sprocket to the front output shaft. Grasp the drive and driven sprocket complete with the chain and lift them at the same time from the drive and driven output shafts.
15. Remove the shift rail by sliding it straight out from the shift fork.
16. Lift out the pump screen and remove the output shaft with the pump assembled on it. If the pump is to be disassembled, remove the four bolts from the pump body. Note the position of the pump front body, pins, spring, rear cover and pump retainer as removed. CAUTION: Do not disassemble oil pump unless the oil pump retaining bracket has been bent or broken, or pump damage is indicated. Indications of pump damage are blueing or blackening of the pump, or loosening of the pump bolts.
17. Remove the oil pan magnet (7L027) from its slot in the case.
18. Remove the high-low shift fork by first rotating it until the roller is free from the cam, then sliding out of engagement from the shift collar hub.
19. Remove the shift collar hub.
20. Turn the front case over and remove the front input yoke to flange seal from the case using a screwdriver.
21. Reaching through the front opening with a pair of snap ring pliers, carefully expand the snap ring on the input shaft allowing it to drop out of the bearing. The front planet (7A398 ), including the input shaft, is serviced as an assembly only. If the bearing or bushing is to be replaced, drive out both of them through the input spline using suitable tools such as a brass drift and a small hammer, being careful not to damage the case.
22. Remove the ring gear (7A153) by prying out the internal snap ring with a screwdriver and lift out the gear.
23. Remove the internal snap ring securing the input shaft bearing to the case.
24. Remove the input shaft bearing using Bearing Cup Replacer T73T-1202-A and Driver Handle T80T-4000-W.
25. Remove the internal snap ring securing the front output shaft bearing in the case.
26. Drive the bearing out from the front of the case using Bearing Cup Replacer T73T-1202-B and Driver Handle T80T-4000-W.
27. Place the shift lever in the NEUTRAL position so the shift cam setscrew can be seen through the hole for the 4WD indicator switch.
28. Remove the setscrew using a hex key tool.
29. Remove the shift lever by sliding it out of the case.
30. Remove the shift cam.
31. Remove the shifter shaft seal (7288 ) by carefully prying it out of the case, being careful not to damage the case.
32. Remove the shift cam, assist spring, and assist spring bushing from the case.

Assembly
Before assembly, lubricate all parts with Motorcraft MERCON%uFFFD ATF XT- 2-QDX or MERCON%uFFFD equivalent. Remove all chips from the bolt holes in the case and rear case.

1. Install the input shaft and the front output shaft bearing in the case using Bearing Cup Replacer T80T-4000-P and Driver Handle T80T-4000-W. Install the internal snap rings retaining the bearing in the case.
2. Drive the front output yoke to flange seal into the case until it is fully seated against the case using Output Shaft Seal Replacer T86T-7034-CH.
3. Install the front output shaft through the lower bearing. The front output shaft is held in place in the case by the front output yoke to flange seal and oil seal slinger. Install the front case yoke onto the front output shaft, then the oil seal, output shaft yoke washer and 32mm shaft nut. Tighten the yoke shaft nut to 203-244 Nm (150-180 lb-ft).
4. Press the needle bearing and bronze bushing into the input shaft and carrier assembly with the appropriate tools, making sure that the bearing and bushing are driven in straight.
5. Install the ring gear into the slots in the case and retain it with the large internal snap rings making sure that it is fully seated.
6. Install the input shaft and front planet in the case through the input shaft bearing, being careful not to damage the gear teeth when aligning them with the ring gear teeth.
7. While supporting the front planet in position, install a new snap ring on the front side of the input shaft bearing, making sure that it is fully seated in the snap ring groove of the input shaft.
8. Install the upper input shaft yoke to flange seal into the case using an appropriate tool until it is fully seated against the case.
9. Install a new shifter shaft seal into the case using an appropriate tool.
10. Install the shift cam detent spring in position in the bushing of the shift cam and in the recess in the case.
11. Assemble the shift cam into the case by sliding the shift shaft and lever through the case and seal into engagement with the shift cam. Install the setscrew through the holes in the case for the 4WD indicator switch.
12. Lubricate all pump parts with clean automatic transmission fluid prior to assembly.
13. Assemble the pump and output shaft as follows:
- a. Place the oil pump cover with the word TOP facing the front of the case.
- b. Install the two pins (with the flats facing toward the rear of the vehicle) with the spring between the pins and place the assembly in the oil pump bore in the output shaft.
- c. Place the oil pump body and pick-up tube over the output shaft and make sure that the pins are riding against the inside of the pump body.
- d. Place the oil pump rear cover with the words TOP REAR facing the rear of the output shaft. NOTE: The word TOP on the front cover and the rear cover should be on the same side.
- e. Install the pump retainer with the tabs facing the front of the transfer case.
- f. Install the four retaining bolts and rotate the output shaft while tightening the bolts to prevent the pump from binding. Tighten bolts to 4-4.5 Nm (36-40 lb-in). NOTE: The output shaft must turn freely within the oil pump. If binding occurs, loosen the four bolts and retighten as outlined.
14. Install the shift collar. Install the high-low shift fork by engaging it with the shift hub flange and rotating it until the roller is engaged with the lower groove of the cam.
15. Install the shift rail through the high-low fork bore and into the rail bore in the case.
16. Install the output shaft and oil pump in the input shaft. Make sure the external splines of the output shaft engage the internal splines of the shift collar hub. Make sure the oil pump retainer and oil filter leg are in the groove and notch of the front case. Install the oil pan magnet in the slot in the front case.
17. Assemble the following components:
- a. Assemble the drive sprocket into the chain.
- b. Assemble the driven sprocket into the chain so the word REAR is facing upward. NOTE: The sprocket engagement spline will face the rear of the vehicle when properly installed.
- c. Place the sprockets and chain as an assembly over the rear and front output shafts.
- d. Install the thrust washer (7119) and snap ring that retains the lower sprocket to the front output shaft.
18. Assemble the 2W-4W lockup as follows:
- a. Position the small end of the tapered compression spring in the lockup collar.
- b. Place the lockup hub over the large end of the spring and compress the spring while installing the internal snap ring. NOTE: The snap ring holds the lockup together.
19. Install the lockup and its shift fork over the external splines of the drive sprocket and the shift rail with the cam follower feature of the fork facing the front of the transfer case.
20. Assemble the 4WD return spring over the shift rail and against the shift fork.
21. Place the lockup hub over the external splines of the output shaft and secure with the appropriate snap ring. Make sure the snap ring is fully seated in the snap ring groove.
22. Press the front output needle bearing in its bore in the rear case using an appropriate tool.
23. Press the rear output shaft bearing into position in the rear case using an appropriate tool. Install bearing snap ring retainer in rear case.
24. Install the rear output shaft yoke to flange seal in the bearing retainer using the appropriate tool and making sure that it is fully seated.
25. Coat the mating surface of the front case with a very small bead of Black Non-Acid Cure Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M4G273-A. CAUTION: If too much silicone rubber is used when sealing the case halves, the excess sealant may plug the oil filter and cause case failure.
26. Place the case halves together making sure that the front output shaft, shift shaft and shift rail are aligned. Install and tighten the 12 No. 50-Torx%uFFFD head bolts to 35-43 Nm (26-32 lb-ft).
27. Install the rear bearing snap ring on the output shaft making sure that the snap ring is fully seated in the groove of the output shaft.
28. Apply a very small bead of Black Non-Acid Cure Silicone Rubber ET7Z-19562-A or equivalent meeting Ford specification ESL-M4G273-A to the face of the rear bearing retainer or rear slip-yoke extension housing (7A039).
29. Place the rear bearing retainer or rear slip-yoke extension housing in its position and secure with the four Torx%uFFFD bolts tightened to 30-49 Nm (22-36 lb-ft).
30. On transfer case with slip-yoke rear bearing retainer housing, remove the yoke to flange seal using a screwdriver. If the bushing in the rear slip yoke extension housing is damaged and must be replaced, it must be replaced with the extension housing as an assembly. The bushing alone cannot be serviced. Install a new seal using Extension Housing Seal Replacer T61L-7657-B.
31. For fixed yoke models, install the rear output shaft case yoke and slinger onto the rear splines of the output shaft. Install the oil seal, output shaft yoke washer and 32mm shaft nut on the output shaft and tighten to 163-203 Nm (120-150 lb-ft).
32. Install the drain plug and tighten to 9-23 Nm (7-17 lb-ft).
33. Install the 4WD indicator switch with aluminum washer into the case. Tighten 4WD indicator switch to 34-47 Nm (25-35 lb-ft).
34. Install the transfer case.
35. Fill transfer case.
36. Start engine, check transfer case for correct operation. Stop engine and check fluid level. Fluid should drip out of level hole. If fluid flows out of level hole, the oil pump may not be functioning properly.
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