What should the rear output shaft end play be on this Ford transfer case?

The end play should be 0.003-0.005 inch. If not within these limits, adjust the shim pack between the speedometer drive gear and rear output shaft outer bearing.

What special tools are called out for the rear drive output shaft bearing cups and seal?

Tool T55P-4616A1 installs the outer cup in the bearing retainer, tool T56T-4616-A2 installs the inner cup, and tool T56T-4616-A presses the bearing retainer seal into the housing.

How is the front output shaft rear bearing removed?

Use the sliding gear as a base and press the bearing from the shaft; the bearing is installed as shown in Fig. 15.

How is the input shaft removed from the adapter housing?

Remove the snap ring from the front of the shaft, then place the adapter housing and input shaft on a press and press the shaft out of the main drive gear and housing.

How is end play checked on the rear output shaft?

Place the bearing retainer and shaft in a vise, install the output shaft flange and torque the retaining nut to specifications, then install a dial indicator on the flange end of the output shaft and check the end play.

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Ford Transfer Case Repair - Output Shaft, Input Shaft & Shift Rail Procedures

Ford manual transmission Group 6 service procedure: removing adapter housing, output shaft and detent rods

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Manual-shift transmission overhaul page (Group 6, p.6-22) covering input shaft, rear drive output shaft and adapter housing teardown; output shaft inner bearing replaced with tool T56T-4616-A2.

AI caption March 2006 · Photo 69 of 206

This is page 6-22 from a Ford shop manual, Group 6 — Manual Shift Transmission, covering parts repair and replacement procedures for a transfer case. It includes three labeled photographs: Fig. 7 shows removing or installing the adapter housing with callouts for the rear output shaft bearing retainer, adapter, sliding gear, shift fork, shift rail link, and front and rear drive shift rails (C 1605-A); Fig. 8 shows removing the front output shaft with the snap ring, main drive gear, sliding gear, front and rear bearings labeled (C 1606-A); Fig. 9 shows removing the detent rods with a magnet (C 1607-A). Step-by-step procedures cover the input shaft (snap ring removal, pressing the shaft out of the main drive gear and housing, seal and bearing replacement), the rear drive output shaft (needle bearing removal, speedometer gear and shim handling, pressing bearings and cups using tools T55P-4616A1, T56T-4616-A2, and T56T-4616-A, and setting end play to 0.003-0.005 inch by adjusting the shim pack), the front drive output shaft rear bearing replacement, and the start of the shift rail oil seal procedure. The page provides overhaul-level disassembly and reassembly instructions for the transfer case internals.

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Frequently asked questions

What should the rear output shaft end play be on this Ford transfer case?: The end play should be 0.003-0.005 inch. If not within these limits, adjust the shim pack between the speedometer drive gear and rear output shaft outer bearing.
What special tools are called out for the rear drive output shaft bearing cups and seal?: Tool T55P-4616A1 installs the outer cup in the bearing retainer, tool T56T-4616-A2 installs the inner cup, and tool T56T-4616-A presses the bearing retainer seal into the housing.
How is the front output shaft rear bearing removed?: Use the sliding gear as a base and press the bearing from the shaft; the bearing is installed as shown in Fig. 15.
How is the input shaft removed from the adapter housing?: Remove the snap ring from the front of the shaft, then place the adapter housing and input shaft on a press and press the shaft out of the main drive gear and housing.
How is end play checked on the rear output shaft?: Place the bearing retainer and shaft in a vise, install the output shaft flange and torque the retaining nut to specifications, then install a dial indicator on the flange end of the output shaft and check the end play.