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Transfer Case - Navigator: Disassembly

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    CAUTION: Use a petroleum-based solvent to clean the transfer case. Seal all openings before cleaning the transfer case exterior. This will prevent entry of dirt and water, which may cause damage to internal components.
  1. Clean the transfer case exterior with solvent and dry with compressed air.
  2. Using the special tool, secure the transfer case to a work bench. Rotate the transfer case so that the output shaft is pointing upward.
    3. Fig 1: Securing Transfer Case To A Work Bench Using Special Tool (307-003)
    GF0046947Courtesy of FORD MOTOR CO.
  3. Drain the fluid from the transfer case, if not done previously.
  4. Using a suitable tool, remove and discard the rear output shaft seal.
    5. Fig 2: Identifying Rear Output Shaft Seal
    GF0046948Courtesy of FORD MOTOR CO.
  5. Remove the inner connector retainer. Using an electrical connector pin extractor tool, remove the coil wire pin (blue wire).
    6. Fig 3: Identifying Inner Connector Retainer
    GF0046949Courtesy of FORD MOTOR CO.
  6. Remove the 2 connector bracket bolts and the connector bracket.
    7. Fig 4: Identifying Connector Bracket Bolts
    GF0046950Courtesy of FORD MOTOR CO.
  7. Remove the 3 coil nuts and washers.
    8. Fig 5: Identifying Coil Nuts & Washers
    GF0046951Courtesy of FORD MOTOR CO.
    NOTE: It is normal to find metal shavings after removing the self-tapping transfer case bolts.
  8. Remove the 20 transfer case cover bolts.
    9. Fig 6: Identifying Transfer Case Cover Bolts
    GF0046952Courtesy of FORD MOTOR CO.
  9. Using the pry bosses, separate the transfer case halves.
    10. Fig 7: Separating Transfer Case Halves Using Pry Bosses
    GF0046953Courtesy of FORD MOTOR CO.
  10. Using the special tool, remove the rear output shaft support bearing.
    • Inspect the bearing for wear or damage. Install a new bearing as necessary.
    11. Fig 8: Removing Rear Output Shaft Support Bearing Using Special Tools (100-001, 308-047)
    GF0046954Courtesy of FORD MOTOR CO.
  11. Using the special tool, remove the front output shaft rear bearing.
    • Inspect the bearing for wear or damage. Install a new bearing as necessary.
    12. Fig 9: Removing Front Output Shaft Support Bearing Using Special Tools (100-001, 308-047)
    GF0046955Courtesy of FORD MOTOR CO.
  12. Remove the snap ring.
    • Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
    13. Fig 10: Inspecting Snap Ring For Wear Or Damage
    GF0046956Courtesy of FORD MOTOR CO.
  13. Remove the washer.
    14. Fig 11: Identifying Washer
    GF0046957Courtesy of FORD MOTOR CO.
  14. Remove the caged thrust bearing assembly.
    • Inspect the bearing for wear or damage. Install a new bearing as necessary.
    15. Fig 12: Identifying Caged Thrust Bearing Assembly
    GF0046958Courtesy of FORD MOTOR CO.
  15. Remove the cam/coil housing.
    16. Fig 13: Identifying Cam/Coil Housing
    GF0046959Courtesy of FORD MOTOR CO.
  16. Remove the 3 steel balls and the cam.
    17. Fig 14: Identifying Steel Balls & Cam
    GF0046960Courtesy of FORD MOTOR CO.
  17. Remove the wave spring.
    18. Fig 15: Identifying Wave Spring
    GF0046961Courtesy of FORD MOTOR CO.
  18. Remove and discard the snap ring.
    19. Fig 16: Identifying Snap Ring
    GF0046962Courtesy of FORD MOTOR CO.
    CAUTION: When removing the clutch pack assembly, do not separate the clutch pack assembly. Keep tension on the clutch pack during removal. Set the clutch pack assembly on the bench in the same position as 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 will occur.
  19. Remove the clutch pack assembly.
    20. Fig 17: Identifying Clutch Pack Assembly
    GF0046963Courtesy of FORD MOTOR CO.
  20. Remove the drive chain and the sprockets as an assembly.
    • Inspect the drive chain for wear or damage. Inspect the sprockets for broken or cracked teeth. Install new components as necessary.
    21. Fig 18: Identifying Drive Chain & Sprockets
    GF0046964Courtesy of FORD MOTOR CO.
  21. Remove the thrust bearing assembly.
    1. Remove the thrust washer.
      • The upper thrust washer may be attached to the sprocket.
    2. Remove the thrust bearing.
    3. Remove the thrust washer.
    4. Inspect the washers and bearing for wear or damage. Install new components as necessary.
    22. Fig 19: Identifying Thrust Washer
    GF0046965Courtesy of FORD MOTOR CO.
  22. Remove and clean the oil pan magnet.
    23. Fig 20: Identifying Oil Pan Magnet
    GF0046966Courtesy of FORD MOTOR CO.
  23. Remove the oil pump assembly.
    24. Fig 21: Identifying Oil Pump Assembly
    GF0046967Courtesy of FORD MOTOR CO.
  24. Remove the output shaft.
    25. Fig 22: Identifying Output Shaft
    GF0046968Courtesy of FORD MOTOR CO.
  25. Remove the input shaft.
    26. Fig 23: Identifying Input Shaft
    GF0046969Courtesy of FORD MOTOR CO.
    NOTE: Do not let the front output shaft fall when removing the snap ring.
  26. Remove the snap ring and the front output shaft.
    • Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
    27. Fig 24: Identifying Snap Ring & Front Output Shaft
    GF0046970Courtesy of FORD MOTOR CO.
    CAUTION: Carefully remove the seal, do not damage the seal bore.
  27. Remove and discard the front output shaft oil seal.
    28. Fig 25: Identifying Front Output Shaft Oil Seal
    GF0046971Courtesy of FORD MOTOR CO.
    CAUTION: Carefully remove the seal, do not damage the seal bore.
  28. Remove and discard the front input shaft seal.
    29. Fig 26: Identifying Front Input Shaft Seal
    GF0046972Courtesy of FORD MOTOR CO.
  29. Using a suitable driver, remove the front input shaft bearing.
    30. Fig 27: Removing Front Input Shaft Bearing Using A Suitable Driver
    GF0046973Courtesy of FORD MOTOR CO.
  30. Using a suitable driver, remove the front output shaft support bearing.
    • Inspect the bearing for wear or damage. Install a new bearing as necessary.
    31. Fig 28: Removing Front Output Shaft Support Bearing Using A Suitable Driver
    GF0046974Courtesy of FORD MOTOR CO.
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