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Home >> Ford >> 2002 >> Explorer 4.6 W, RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 6 (Transfer Case - Automatic Shift) >> Disassembly And Assembly >> Transfer Case >> Disassembly >> Disassembled View

Disassembled View

WARNING: This page is about a different variant/trim than selected.
Fig 1: Exploded View Of Transfer Case (1 Of 2)
G02168818Courtesy of FORD MOTOR CO.
Fig 2: Exploded View Of Transfer Case (2 Of 2)
G02168819Courtesy of FORD MOTOR CO.
  1. Remove the transfer case. For additional information, refer to TRANSFER CASE - MANUAL TRANSMISSION .
  2. Remove the dampener.
  3. Remove the heat shield.
    Fig 3: Removing Heat Shield
    G02168820Courtesy of FORD MOTOR CO.
    4. WARNING: Make sure the Holding Fixture lock pin is secure.
    Fig 4: Securing Transfer Case To Bench
    G02168821Courtesy of FORD MOTOR CO.
  4. Using the special tool, secure the transfer case to the bench.
  5. Index-mark the rear output flange and the rear output shaft.
    Fig 5: Marking Rear Output Flange And Rear Output Shaft
    G02168822Courtesy of FORD MOTOR CO.
  6. Using the special tool to hold the rear output flange, remove the nut.
    Fig 6: Installing Special Tool
    G02168823Courtesy of FORD MOTOR CO.
  7. Remove the rear output flange and the output shaft yoke washer.
    Fig 7: Removing Rear Output Flange
    G02168824Courtesy of FORD MOTOR CO.
  8. Remove the oil seal.
    Fig 8: Removing Oil Seal
    G02168825Courtesy of FORD MOTOR CO.
  9. Using the special tools, remove the oil seal.
    Fig 9: Removing Oil Seal
    G02168826Courtesy of FORD MOTOR CO.
  10. Remove the coil wire pin from the electrical connector.
    1. Remove the connector interlock.
    2. Remove the coil wire pin.
      • Use electrical connector pin extractor tool.
        Fig 10: Removing Coil Wire Pin From Electrical Connector
        G02168827Courtesy of FORD MOTOR CO.
  11. Remove the front and rear output shaft speed sensor bolts. Carefully remove the sensors from the transfer case.
    Fig 11: Removing Front And Rear Output Shaft Speed Sensor Bolts
    G02168828Courtesy of FORD MOTOR CO.
    Fig 12: Locating Bolt
    G02168829Courtesy of FORD MOTOR CO.
  12. Remove the four bolts and the transfer case shift motor.
    Fig 13: Removing Bolts And Transfer Case Shift Motor
    G02168830Courtesy of FORD MOTOR CO.
    13. NOTE: Inspect the tone wheel teeth for damage.
  13. If necessary, remove and discard the tone wheel.
  14. Remove the 17 bolts.
    Fig 14: Removing Bolts
    G02168831Courtesy of FORD MOTOR CO.
  15. Remove the clutch coil assembly nuts.
    Fig 15: Removing Clutch Coil Assembly Nuts
    G02168832Courtesy of FORD MOTOR CO.
  16. Separate the transfer case halves at the transfer case pry bosses.
    Fig 16: Separating Transfer Case Halves
    G02168833Courtesy of FORD MOTOR CO.
  17. Using the special tools, remove the front output shaft rear bearing and the rear output shaft support bearing.
    Fig 17: Removing Front Output Shaft Rear Bearing
    G02168834Courtesy of FORD MOTOR CO.
    Fig 18: Installing Special Tool
    G02168835Courtesy of FORD MOTOR CO.
  18. Remove the thrust bearing.
    Fig 19: Removing Thrust Bearing
    G02168836Courtesy of FORD MOTOR CO.
  19. Remove the cam and coil housing assembly.
    Fig 20: Removing Cam And Coil Housing Assembly
    G02168837Courtesy of FORD MOTOR CO.
  20. Remove the apply cam and balls.
    1. Remove the steel balls.
    2. Remove the apply cam.
      Fig 21: Removing Apply Cam And Balls
      G02168838Courtesy of FORD MOTOR CO.
  21. Remove the wave spring.
    Fig 22: Removing Wave Spring
    G02168839Courtesy of FORD MOTOR CO.
  22. Remove the snap ring.
    Fig 23: Removing Snap Ring
    G02168840Courtesy of FORD MOTOR CO.
    23. CAUTION: When removing or installing the clutch pack assembly, do not separate the clutch pack assembly. Keep tension on the clutch pack upon removal. Set the clutch pack assembly on the bench in the same position as it was located in the transfer case. The thrust washer in the lower clutch pack uses tabs to hold it in place. If the thrust washer is not in place, a transfer case clearance problem can occur.
    Fig 24: Removing Clutch Pack Assembly
    G02168841Courtesy of FORD MOTOR CO.
  23. Remove the clutch pack assembly.
  24. Remove the tone wheel.
    Fig 25: Removing Tone Wheel
    G02168842Courtesy of FORD MOTOR CO.
  25. Remove the drive chain and the sprockets as an assembly.
    Fig 26: Removing Drive Chain And Sprockets
    G02168843Courtesy of FORD MOTOR CO.
  26. Remove and clean the oil pan magnet.
    Fig 27: Locating Magnet
    G02168844Courtesy of FORD MOTOR CO.
  27. Remove the thrust washer.
    Fig 28: Removing Thrust Washer
    G02168845Courtesy of FORD MOTOR CO.
    28. CAUTION: Do not disassemble the pump assembly.
    Fig 29: Removing Pump Assembly
    G02168846Courtesy of FORD MOTOR CO.
  28. Remove the pump assembly and the rear output shaft as an assembly.
    29. CAUTION: Do not disassemble the electric shift cam assembly.
    Fig 30: Removing Electric Shift Cam Assembly
    G02168847Courtesy of FORD MOTOR CO.
  29. Remove the electric shift cam assembly.
  30. Remove the reduction shift fork and the high-low collar as an assembly.
    Fig 31: Removing Reduction Shift Fork
    G02168848Courtesy of FORD MOTOR CO.
  31. Remove the shift rail.
    Fig 32: Removing Shift Rail
    G02168849Courtesy of FORD MOTOR CO.
  32. Using the special tool, remove the oil seal.
    Fig 33: Removing Oil Seal
    G02168850Courtesy of FORD MOTOR CO.
  33. Remove the front planetary gear set assembly.
    1. Expand the snap ring.
    2. Remove the front planetary gear set assembly.
      Fig 34: Removing Front Planetary Gear Set Assembly
      G02168851Courtesy of FORD MOTOR CO.
  34. Remove the ring gear, if necessary.
    1. Remove the snap ring.
    2. Remove the ring gear.
      Fig 35: Removing Ring Gear
      G02168852Courtesy of FORD MOTOR CO.
  35. Using a drift and hammer, remove the output shaft bushing and bearing, if necessary.
    Fig 36: Removing Output Shaft Bushing And Bearing
    G02168853Courtesy of FORD MOTOR CO.
  36. If planetary gear carrier support bearing removal is necessary, remove the snap ring.
    Fig 37: Removing Snap Ring
    G02168854Courtesy of FORD MOTOR CO.
  37. Using a suitable press and the special tool, remove the planetary gear carrier support bearing.
    Fig 38: Removing Planetary Gear Carrier Support Bearing
    G02168855Courtesy of FORD MOTOR CO.
  38. Remove the dampener snubber.
    Fig 39: Removing Dampener Snubber
    G02168856Courtesy of FORD MOTOR CO.
  39. Holding the front output shaft and flange, remove the snap ring and the front output shaft and flange.
    Fig 40: Removing Snap Ring And Front Output Shaft And Flange
    G02168857Courtesy of FORD MOTOR CO.
    Fig 41: Locating Snap Ring
    G02168858Courtesy of FORD MOTOR CO.
  40. Using the special tools, remove the oil seal.
    Fig 42: Removing Oil Seal
    G02168859Courtesy of FORD MOTOR CO.
  41. Using the special tools, remove the front output shaft support bearing.
    Fig 43: Removing Front Output Shaft Support Bearing
    G02168860Courtesy of FORD MOTOR CO.
  42. Remove the shifter shaft seal.
    Fig 44: Removing Shifter Shaft Seal
    G02168861Courtesy of FORD MOTOR CO.
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