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Transfer Case: Disassembly

WARNING: This page is about a different car, the 2002 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Transfer Case Components (1 Of 2)
G02153305Courtesy of FORD MOTOR CO.
Fig 2: Identifying Transfer Case Components (2 Of 2)
G02153306Courtesy of FORD MOTOR CO.
  1. Remove the transfer case from the vehicle. For additional information, refer to TRANSFER CASE .
  2. Attach the transfer case to the special tool.
    Fig 3: Attaching Transfer Case To Special Tool
    G02153307Courtesy of FORD MOTOR CO.
    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.
    Fig 4: Removing Flange Nut & Washer
    G02153308Courtesy of FORD MOTOR CO.
  3. Use the special tool to prevent the flange from turning. Remove and discard the nut and the washer.
  4. Using a suitable puller, remove the flange.
    Fig 5: Removing Flange
    G02153309Courtesy of FORD MOTOR CO.
  5. Remove the oil seal if it remains on the rear output shaft.
    Fig 6: Removing Oil Seal
    G02153310Courtesy of FORD MOTOR CO.
  6. Using the special tool, remove the oil seal.
    Fig 7: Removing Oil Seal
    G02153311Courtesy of FORD MOTOR CO.
  7. Remove the spacer.
    Fig 8: Removing Spacer
    G02153312Courtesy of FORD MOTOR CO.
  8. Remove the bolts retaining the harness to the motor assembly and connector.
    Fig 9: Removing Motor Assembly & Connector Harness Retainer Bolts
    G02153313Courtesy of FORD MOTOR CO.
  9. Remove the rear bolt.
    Fig 10: Removing Rear Bolt
    G02153314Courtesy of FORD MOTOR CO.
  10. Remove the front bolt and the motor assembly and connector.
    Fig 11: Removing Front Bolt, Motor Assembly & Connector
    G02153315Courtesy of FORD MOTOR CO.
  11. Remove the bolts that retain the transfer case cover to the transfer case.
    Fig 12: Removing Transfer Case Cover Bolts
    G02153316Courtesy of FORD MOTOR CO.
  12. Remove the bolts that retain the transfer case to the transfer case cover.
    Fig 13: Removing Bolts Retaining Transfer Case-To-Transfer Case Cover
    G02153317Courtesy of FORD MOTOR CO.
    13. NOTE: Position the assembly so that the front of the transfer case is facing downward.
    Fig 14: Separating Transfer Case Cover From Transfer Case
    G02153318Courtesy of FORD MOTOR CO.
  13. Insert a breaker bar between the pry bosses, and separate the transfer case cover from the transfer case.
  14. Remove the snap ring that retains the bearing in the case.
    Fig 15: Removing Snap Ring Retaining Bearing In Case
    G02153319Courtesy of FORD MOTOR CO.
  15. Using the special tools, remove the bearing.
    Fig 16: Removing Bearing
    G02153320Courtesy of FORD MOTOR CO.
  16. Using the special tools, remove the needle bearing.
    Fig 17: Removing Needle Bearing
    G02153321Courtesy of FORD MOTOR CO.
  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.
    4. Remove the electric shift cam assembly.
    5. Remove the shift rail.
    Fig 18: Removing Transfer Case Components
    G02153322Courtesy of FORD MOTOR CO.
  18. Remove the snap ring.
    Fig 19: Removing Snap Ring
    G02153323Courtesy of FORD MOTOR CO.
  19. Remove the lockup hub and the sleeve return spring from the lockup collar.
    Fig 20: Removing Lockup Hub & Sleeve Return Spring
    G02153324Courtesy of FORD MOTOR CO.
  20. Remove the snap ring and the spacer.
    Fig 21: Removing Snap Ring & Spacer
    G02153325Courtesy of FORD MOTOR CO.
  21. Remove the drive chain, the driven sprocket, and the drive sprocket as an assembly.
    Fig 22: Removing Drive Chain, Driven Sprocket & Drive Sprocket Assembly
    G02153326Courtesy of FORD MOTOR CO.
  22. Remove the magnet and the oil strainer from the slot in the transfer case.
    Fig 23: Removing Magnet & Oil Strainer
    G02153327Courtesy of FORD MOTOR CO.
  23. Remove the rear output shaft and the pump assembly as an assembly.
    Fig 24: Removing Rear Output Shaft & Pump Assembly
    G02153328Courtesy of FORD MOTOR CO.
  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.
    Fig 25: Aligning Keyway In Cover & Rear Output Shaft Spring Pin
    G02153329Courtesy of FORD MOTOR CO.
    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.
    Fig 26: Measuring Pump Drive Pin Height
    G03276435Courtesy of FORD MOTOR CO.
  25. 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.
    26. CAUTION: Do not let the front output shaft assembly fall out of the case while removing the snap ring.
    Fig 27: Removing Snap Ring
    G02153330Courtesy of FORD MOTOR CO.
  26. Remove the snap ring. Discard the snap ring if deformed during removal.
  27. Remove the front output shaft assembly.
    Fig 28: Removing Front Output Shaft Assembly
    G02153331Courtesy of FORD MOTOR CO.
  28. Remove the reduction fork assembly and the reduction hub as an assembly.
    Fig 29: Removing Reduction Fork & Reduction Hub Assemblies
    G02153332Courtesy of FORD MOTOR CO.
  29. Remove the six bolts retaining the front adapter assembly to the case.
    Fig 30: Removing Front Adapter Assembly Retaining Bolts
    G02153333Courtesy of FORD MOTOR CO.
  30. Remove the front adapter assembly, the input shaft assembly, and the complete carrier assembly as an assembly.
    Fig 31: Removing Front Adapter, Input Shaft & Complete Carrier Assemblies
    G02153334Courtesy of FORD MOTOR CO.
  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.
    Fig 32: Expand Tangs Of Large Snap Ring/Removing Complete Carrier Assembly
    G02153335Courtesy of FORD MOTOR CO.
  32. Remove the large snap ring from the front adapter.
    Fig 33: Removing Large Snap Ring From Front Adapter
    G02153336Courtesy of FORD MOTOR CO.
  33. Using a suitable tool, remove the oil seal from the front adapter.
    Fig 34: Removing Oil Seal From Front Adapter
    G02153337Courtesy of FORD MOTOR CO.
  34. Remove the snap ring.
    Fig 35: Removing Snap Ring
    G02153338Courtesy of FORD MOTOR CO.
  35. Using the special tool and a suitable press, remove the bearing.
    Fig 36: Removing Bearing
    G02153339Courtesy of FORD MOTOR CO.
  36. Remove the thrust washer and the input shaft assembly.
    Fig 37: Removing Thrust Washer & Input Shaft Assembly
    G02153340Courtesy of FORD MOTOR CO.
  37. Remove the snap ring, the thrust plate, and the sun gear.
    Fig 38: Removing Snap Ring, Thrust Plate & Sun Gear
    G02153341Courtesy of FORD MOTOR CO.
    38. NOTE: Remove and discard both the sleeve bearing and the needle bearing if either one is worn/damaged.
    Fig 39: Removing Needle Bearing & Sleeve Bearing
    G02153342Courtesy of FORD MOTOR CO.
  38. Using the special tools and a suitable press, remove the needle bearing and the sleeve bearing from the input shaft.
  39. Using a suitable tool, remove the oil seal.
    Fig 40: Removing Oil Seal
    G02153343Courtesy of FORD MOTOR CO.
  40. Remove the snap ring retaining the bearing to the case.
    Fig 41: Removing Snap Ring Retaining Bearing To Case
    G02153344Courtesy of FORD MOTOR CO.
  41. Using the special tools, remove the bearing.
    Fig 42: Removing Bearing
    G02153345Courtesy of FORD MOTOR CO.
  42. Using a suitable tool, remove the oil seal.
    Fig 43: Removing Oil Seal
    G02153346Courtesy of FORD MOTOR CO.
  43. Remove the shift fork facings.
    Fig 44: Removing Shift Fork Facings
    G02153347Courtesy of FORD MOTOR CO.
  44. Remove the electric shift cam from the shift shaft.
    Fig 45: Removing Electric Shift Cam From Shift Shaft
    G02153348Courtesy of FORD MOTOR CO.
    45. WARNING: Keep fingers away from spring ends. Failure to follow these instructions can result in personal injury.
    Fig 46: Removing Torsion Spring & Spacer From Shift Shaft
    G02153349Courtesy of FORD MOTOR CO.
  45. Remove the torsion spring and the spacer from the shift shaft.
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