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Transfer Case — Vehicles With: 5-Speed Manual Transmission - MT75/6-Speed 308-07A-1 Manual Transmission - MT82 308-07A-1 SECTION 308-07A Transfer Case — Vehicles With: 5-Speed Manual Transmission - MT75/6-Speed Manual Transmission - MT82 VEHICLE APPLICATION: 2011.50 Ranger CONTENTS PAGE SPECIFICATIONS Specifications 308-07A-2 DESCRIPTION AND OPERATION Transfer Case 308-07A-3 GENERAL PROCEDURES Transfer Case Draining and Filling Transfer Case Fluid Level Check 308-07A-4 308-07A-5 REMOVAL Transfer Case 308-07A-6 DISASSEMBLY AND ASSEMBLY Transfer Case 308-07A-9 INSTALLATION Transfer Case 308-07A-23 Transfer Case — Vehicles With: 5-Speed Manual Transmission - MT75/6-Speed 308-07A-2 308-07A-2 Manual Transmission - MT82 SPECIFICATIONS Description Transfer Case Oil Oil capacity 2011.50 Ranger Specification WSS-M2C938-A 1.2L G1539161en Transfer Case — Vehicles With: 5-Speed Manual Transmission - MT75/6-Speed 308-07A-3 Manual Transmission - MT82 308-07A-3 DESCRIPTION AND OPERATION Transfer Case Item Description Breather tube Motor Oil filler plug Drain plug Damper 2011.50 Ranger G1273769en Transfer Case — Vehicles With: 5-Speed Manual Transmission - MT75/6-Speed 308-07A-4 Manual Transmission - MT82 308-07A-4 GENERAL PROCEDURES Transfer Case Draining and Filling Remove the drain plug and the seal • Drain the oil into a suitable container • Tighten the drain plug with a new seal • Tightening torque 19-30 Nm Remove the filler plug and seal and add the specified amount and type of oil through the filler plug hole until the level reaches the bottom of the filler plug hole • Transfer oil type: Mercon® Multi-purpose AFT XT-2-QDXCapacity (approximate quantity): 1.85 L {1.95 US qt, 1.63 lmp qt} • Tighten the filler plug with a new seal • Tightening torque 19-30 Nm 2011.50 Ranger G1273770en Transfer Case — Vehicles With: 5-Speed Manual Transmission - MT75/6-Speed 308-07A-5 308-07A-5 Manual Transmission - MT82 GENERAL PROCEDURES Transfer Case Fluid Level Check Materials Name Automatic Transmission Oil C-ML5 7U7J-M2C938-AA Specification WSS-M2C938-A Motorcraft® MERCON® LV Automatic Transmission Fluid XT-10-QLVC Check Check the component for leaks Transfer case Fluid Level Check should only be carried out if an oil leak was identified Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation) NOTE: Make sure that the vehicle is standing on a level surface Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) Wait for three minutes and check if X: - mm Material: transmission fluid WSS-M2C938-A (Automatic Transmission Oil C-ML5 / 7U7J-M2C938-AA; Motorcraft® MERCON® LV Automatic Transmission Fluid / XT-10-QLVC) Torque: 35 Nm 2011.50 Ranger G1517165en Transfer Case — Vehicles With: 5-Speed Manual Transmission - MT75/6-Speed 308-07A-6 Manual Transmission - MT82 308-07A-6 REMOVAL Transfer Case Removal General Equipment Transmission Jack Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures) Refer to: Jacking (100-02 Jacking and Lifting, Description and Operation) Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) Refer to: Driveshaft - 4WD (205-01 Driveshaft, Removal and Installation) Refer to: Front Driveshaft - 4WD (205-01 Driveshaft, Removal and Installation) 2011.50 Ranger G1398642en Transfer Case — Vehicles With: 5-Speed Manual Transmission - MT75/6-Speed 308-07A-7 Manual Transmission - MT82 308-07A-7 REMOVAL General Equipment: Transmission Jack 2011.50 Ranger G1398642en Transfer Case — Vehicles With: 5-Speed Manual Transmission - MT75/6-Speed 308-07A-8 Manual Transmission - MT82 308-07A-8 REMOVAL 10 11 2011.50 Ranger G1398642en Transfer Case — Vehicles With: 5-Speed Manual Transmission - MT75/6-Speed 308-07A-9 308-07A-9 Manual Transmission - MT82 DISASSEMBLY AND ASSEMBLY Transfer Case Special Tool(s) / General Equipment 100-001 Slide Hammer 205-072 Universal Flange Holding Wrench 205-078 Remover, Drive Pinion Seal 205-310 Remover, Bearing/Gear 308-375 Remover, Input Shaft Seal Bearing Separator Hydraulic Press Puller Punch Materials Name Silicone Sealant LB 2U7J-M4G323-AA Specification WSE-M4G323-A4 Silicone Gasket and Sealant TA-30 Automatic Transmission Oil C-ML5 2011.50 Ranger WSS-M2C938-A G1398645en Transfer Case — Vehicles With: 5-Speed Manual Transmission - MT75/6-Speed 308-07A-10 308-07A-10 Manual Transmission - MT82 DISASSEMBLY AND ASSEMBLY Name Specification 7U7J-M2C938-AA Motorcraft® MERCON® LV Automatic Transmission Fluid XT-10-QLVC Disassembly WARNING: Be prepared to collect escaping fluids Special Tool(s): 205-072 NOTE: Note the position of the component before removal NOTE: This step is not necessary when installing a new shift motor 2011.50 Ranger General Equipment: Puller Special Tool(s): 205-078 G1398645en Transfer Case — Vehicles With: 5-Speed Manual Transmission - MT75/6-Speed 308-07A-11 Manual Transmission - MT82 308-07A-11 DISASSEMBLY AND ASSEMBLY Special Tool(s): 205-072 10 Special Tool(s): 308-375, 100-001 General Equipment: Puller 11 Special Tool(s): 205-078 2011.50 Ranger G1398645en Transfer Case — Vehicles With: 5-Speed Manual Transmission - MT75/6-Speed 308-07A-12 Manual Transmission - MT82 308-07A-12 DISASSEMBLY AND ASSEMBLY 12 Using a suitable separator tool on the locations shown separate the front and rear casing 14 General Equipment: Punch 15 13 2011.50 Ranger 16 G1398645en Transfer Case — Vehicles With: 5-Speed Manual Transmission - MT75/6-Speed 308-07A-13 Manual Transmission - MT82 308-07A-13 DISASSEMBLY AND ASSEMBLY 17 General Equipment: Hydraulic Press 18 NOTE: Remove the dissengage pin from the control shift rod groove 21 Special Tool(s): 205-310 General Equipment: Hydraulic Press 19 22 20 Special Tool(s): 205-310 2011.50 Ranger G1398645en Transfer Case — Vehicles With: 5-Speed Manual Transmission - MT75/6-Speed 308-07A-14 Manual Transmission - MT82 308-07A-14 DISASSEMBLY AND ASSEMBLY 23 NOTE: Turn the rod as you remove it 26 24 27 25 NOTE: Use a new snap ring 2011.50 Ranger CAUTION: Make sure the shaft is not damaged 28 General Equipment: Hydraulic Press G1398645en Transfer Case — Vehicles With: 5-Speed Manual Transmission - MT75/6-Speed 308-07A-15 Manual Transmission - MT82 308-07A-15 DISASSEMBLY AND ASSEMBLY 29 General Equipment: Hydraulic Press 30 33 31 34 32 General Equipment: Bearing Separator 2011.50 Ranger G1398645en Transfer Case — Vehicles With: 5-Speed Manual Transmission - MT75/6-Speed 308-07A-16 308-07A-16 Manual Transmission - MT82 DISASSEMBLY AND ASSEMBLY 35 38 NOTE: Make sure that the internal gear is installed with the groove facing up into the front case Assembly 36 Torque: 4.5 Nm 39 Tool to be added to odyssey 37 40 2011.50 Ranger CAUTION: Make sure the maingear is not damaged G1398645en Transfer Case — Vehicles With: 5-Speed Manual Transmission - MT75/6-Speed 308-07A-17 308-07A-17 Manual Transmission - MT82 DISASSEMBLY AND ASSEMBLY 41 44 CAUTION: Make sure the maingear is not damaged 42 45 NOTE: Insert pin on the fork assembly into hole in the bracket of the shift rod assembly 43 General Equipment: Hydraulic Press 46 NOTE: Use a new snap ring 2011.50 Ranger G1398645en Transfer Case — Vehicles With: 5-Speed Manual Transmission - MT75/6-Speed 308-07A-18 Manual Transmission - MT82 308-07A-18 DISASSEMBLY AND ASSEMBLY 47 NOTE: Locate L-H shift rod into hole in front case as shown 50 51 General Equipment: Hydraulic Press 48 NOTE: Set the H-L shift rod assembly pin into the groove of the control shift rod NOTE: Locate control shift rod into hole in front case as shown 52 Tool to be added to odyssey General Equipment: Hydraulic Press 49 2011.50 Ranger G1398645en Transfer Case — Vehicles With: 5-Speed Manual Transmission - MT75/6-Speed 308-07A-19 308-07A-19 Manual Transmission - MT82 DISASSEMBLY AND ASSEMBLY 53 56 NOTE: Install in the correct orientation of 2-4 sleeve 54 57 55 NOTE: Set the 2-4 shift rod assembly pin into the groove of the control shift rod 58 CAUTION: Make sure the oil pump is installed in the range of the rib as shown 59 Tool to be added to odyssey 2011.50 Ranger G1398645en Transfer Case — Vehicles With: 5-Speed Manual Transmission - MT75/6-Speed 308-07A-20 Manual Transmission - MT82 308-07A-20 DISASSEMBLY AND ASSEMBLY General Equipment: Hydraulic Press 60 61 CAUTION: Make sure that no excess sealant residue is evident Material: sealant WSE-M4G323-A4 (Silicone Sealant LB / 2U7J-M4G323-AA; Silicone Gasket and Sealant / TA-30) 62 Torque: 45 Nm 63 NOTE: Apply petroleum jelly to the outer circumference of the oil seal 2011.50 Ranger G1398645en