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Transfer Case: Disassembly

WARNING: This page is about a different variant/trim than selected.
Fig 1: Exploded View Of Transfer Case
G03915452Courtesy of FORD MOTOR CO.
Fig 2: Identifying Transfer Case Components
G03915453Courtesy of FORD MOTOR CO.
  1. Remove the transfer case (7005) 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
    G03915454Courtesy of FORD MOTOR CO.
    3. CAUTION: Index-mark the rear output shaft and the flange (7B214).
    CAUTION: The nut has a self-locking feature. Discard the nut after removing it.
    Fig 4: Removing Nut And Washer
    G03915412Courtesy of FORD MOTOR CO.
  3. Use the special tool to prevent the flange from turning. Remove the nut and the washer (7B368). Discard the nut.
  4. Using a suitable puller, remove the flange.
    Fig 5: Removing Flange
    G03915413Courtesy of FORD MOTOR CO.
  5. Remove the oil seal (7052) if it remains on the rear output shaft.
    Fig 6: Removing Oil Seal Remains On Rear Output Shaft
    G03915414Courtesy of FORD MOTOR CO.
  6. Using the special tool, remove the oil seal (7B215).
    Fig 7: Removing Oil Seal (7B215)
    G03915415Courtesy of FORD MOTOR CO.
  7. Remove the spacer (7072).
    Fig 8: Removing Spacer (7072)
    G03915459Courtesy of FORD MOTOR CO.
  8. Remove the two bolts retaining the harness to the motor assembly and connector.
    Fig 9: Removing Two Bolts Retaining Harness To Motor Assembly
    G03915460Courtesy of FORD MOTOR CO.
  9. Remove the rear bolt.
    Fig 10: Removing Rear Bolt
    G03915461Courtesy of FORD MOTOR CO.
  10. Remove the front bolt and the motor assembly and connector.
    Fig 11: Removing Front Bolt And Motor Assembly
    G03915434Courtesy of FORD MOTOR CO.
  11. Remove the bolts that retain the transfer case cover to the transfer case.
    Fig 12: Removing Bolts Retain Transfer Case Cover To Transfer Case
    G03915463Courtesy of FORD MOTOR CO.
  12. Remove the bolts that retain the transfer case to the transfer case cover.
    Fig 13: Removing Bolts Retain Transfer Case To Transfer Case Cover
    G03915464Courtesy of FORD MOTOR CO.
    13. NOTE: Position the assembly so that the front of the transfer case is facing downward.
    Fig 14: Positioning Assembly So Front Of Transfer Case
    G03915465Courtesy 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 (7025) in the case.
    Fig 15: Removing Snap Ring Retains Bearing (7025) In Case
    G03915466Courtesy of FORD MOTOR CO.
  15. Using the special tools, remove the bearing.
    Fig 16: Removing Bearing
    G03915467Courtesy of FORD MOTOR CO.
  16. Using the special tools, remove the needle bearing (7127).
    Fig 17: Removing Needle Bearing
    G03915468Courtesy of FORD MOTOR CO.
  17. Remove the following:
    1. Remove the shift collar hub (7100).
    2. Remove the return spring (7219).
    3. Remove the lockup collar (7106) and the lockup fork (7289) as an assembly.
    4. Remove the electric shift cam assembly.
    5. Remove the shift rail (7240).
      Fig 18: Removing Electric Shift Cam Assembly
      G03915469Courtesy of FORD MOTOR CO.
  18. Remove the snap ring.
    Fig 19: Removing Snap Ring
    G03915470Courtesy of FORD MOTOR CO.
  19. Remove the lockup hub (7D164) and the sleeve return spring (7D126) from the lockup collar.
    Fig 20: Removing Lockup Hub (7D164) And Sleeve Return Spring (7D126)
    G03915471Courtesy of FORD MOTOR CO.
  20. Remove the snap ring and the spacer (7119).
    Fig 21: Removing Snap Ring And Spacer
    G03915472Courtesy of FORD MOTOR CO.
  21. Remove the drive chain, the driven sprocket, and the drive sprocket (7177) as an assembly.
    Fig 22: Removing Drive Chain Driven Sprocket
    G03915473Courtesy of FORD MOTOR CO.
  22. Remove the magnet (7E290) and the oil strainer (7A098) from the slot in the transfer case.
    Fig 23: Removing Magnet (7E290) And Oil Strainer (7A098) From Slot In Transfer Case
    G03915474Courtesy of FORD MOTOR CO.
  23. Remove the rear output shaft (7061) and the pump assembly (7A149) as an assembly.
    Fig 24: Removing Rear Output Shaft (7061) And Pump Assembly
    G03915475Courtesy of FORD MOTOR CO.
  24. Rotate the pump assembly to align the keyway in the cover and the spring pin (7B362) in the rear output shaft, and separate the pump from the shaft.
    Fig 25: Rotating Pump Assembly
    G03915476Courtesy of FORD MOTOR CO.
    25. CAUTION: Do not let the front output shaft assembly (7061) fall out of the case while removing the snap ring.
    Fig 26: Removing Snap Ring
    G03915477Courtesy of FORD MOTOR CO.
  25. Remove the snap ring.
  26. Remove the front output shaft assembly.
    Fig 27: Removing Front Output Shaft Assembly
    G03915478Courtesy of FORD MOTOR CO.
  27. Remove the reduction fork assembly (7289) and the reduction hub (7100) as an assembly.
    Fig 28: Removing Reduction Fork Assembly (7289) And Reduction Hub (7100) As An Assembly
    G03915479Courtesy of FORD MOTOR CO.
  28. Remove the six bolts retaining the front adapter assembly (7050) to the case.
    Fig 29: Removing Six Bolts Retaining Front Adapter Assembly
    G03915480Courtesy of FORD MOTOR CO.
  29. Remove the front adapter assembly, the input shaft assembly (7017), and the complete carrier assembly (7A398) as an assembly.
    Fig 30: Removing Front Adapter Assembly Input Shaft Assembly
    G03915481Courtesy of FORD MOTOR CO.
  30. 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 31: Removing Complete Carrier Assembly
    G03915482Courtesy of FORD MOTOR CO.
  31. Remove the large snap ring from the front adapter.
    Fig 32: Removing Large Snap Ring From Front Adapter
    G03915483Courtesy of FORD MOTOR CO.
  32. Using a suitable tool, remove the oil seal (7B215) from the front adapter.
    Fig 33: Removing Oil Seal (7B215) From Front Adapter
    G03915484Courtesy of FORD MOTOR CO.
  33. Remove the snap ring.
    Fig 34: Removing Snap Ring
    G03915485Courtesy of FORD MOTOR CO.
  34. Using the special tool and a suitable press, remove the bearing (7025).
    Fig 35: Removing Bearing
    G03915486Courtesy of FORD MOTOR CO.
  35. Remove the thrust washer (7A358) and the input shaft assembly.
    Fig 36: Removing Thrust Washer (7A358) And Input Shaft Assembly
    G03915487Courtesy of FORD MOTOR CO.
  36. Remove the snap ring, the thrust plate (7B066), and the sun gear (7D063).
    Fig 37: Removing Snap Ring Thrust Plate (7B066), And Sun Gear
    G03915488Courtesy of FORD MOTOR CO.
    37. NOTE: Remove and discard both the sleeve bearing (7065) and the needle bearing (7120) if either one is worn/damaged.
    Fig 38: Removing And Discarding Both Sleeve Bearing (7065) And Needle Bearing
    G03915489Courtesy of FORD MOTOR CO.
  37. Using the special tools and a suitable press, remove the needle bearing and the sleeve bearing from the input shaft.
  38. Using a suitable tool, remove the oil seal (7B215).
    Fig 39: Removing Oil Seal
    G03976055Courtesy of FORD MOTOR CO.
  39. Remove the snap ring retaining the bearing (7025) to the case.
    Fig 40: Removing Snap Ring Retaining Bearing (7025) To Case
    G03915491Courtesy of FORD MOTOR CO.
  40. Using the special tools, remove the bearing.
    Fig 41: Removing Bearing
    G03915492Courtesy of FORD MOTOR CO.
  41. Using a suitable tool, remove the oil seal (7B216).
    Fig 42: Removing Oil Seal
    G03915493Courtesy of FORD MOTOR CO.
  42. Remove the shift fork facings (7C430).
    Fig 43: Removing Shift Fork Facings
    G03915494Courtesy of FORD MOTOR CO.
  43. Remove the electric shift cam (7F063) from the shift shaft (7N095).
    Fig 44: Removing Electric Shift Cam (7F063) From Shift Shaft
    G03915495Courtesy of FORD MOTOR CO.
    44. WARNING: Keep fingers away from spring ends. Failure to follow these instructions may result in personal injury.
    Fig 45: Removing Torsion Spring (7W074) And Spacer (7Z112) From Shift Shaft
    G03915496Courtesy of FORD MOTOR CO.
  44. Remove the torsion spring (7W074) and the spacer (7Z112) from the shift shaft.
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