Ford F150 Pickup. Instruction - part 1987

Fig. 107: Identifying Transfer Case Bolt Tightening Sequence 
Courtesy of FORD MOTOR CO. 

30. Install the rear output shaft snap ring. 

z

Lift up on the output shaft while installing the snap ring. 

 

2003 Ford Pickup F150 

2003 TRANSMISSIONS Transfer Case - F150 Pickup

  

Fig. 108: Installing Rear Output Shaft Snap Ring 
Courtesy of FORD MOTOR CO. 

NOTE:

Place the speed sensor tone wheel into a suitable gear and bearing heater. 
Heat the tone wheel to 425°F.

 

2003 Ford Pickup F150 

2003 TRANSMISSIONS Transfer Case - F150 Pickup

  

Fig. 109: Installing Speed Sensor Tone Wheel 
Courtesy of FORD MOTOR CO. 

31. Install the speed sensor tone wheel, if equipped. 

1. Install the tone wheel spacer clip against the snap ring.  

2. Slide the heated tone wheel onto the output shaft. Position it against the spacer.  

32. Apply a small bead of sealant to the transfer case cover and extension housing mating surfaces. 

 

2003 Ford Pickup F150 

2003 TRANSMISSIONS Transfer Case - F150 Pickup

  

Fig. 110: Locating Extension Housing Mating Surface For Applying Sealant 
Courtesy of FORD MOTOR CO. 

33. 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. 

 

2003 Ford Pickup F150 

2003 TRANSMISSIONS Transfer Case - F150 Pickup