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Transfer Case - 1-Speed Torque-On-Demand: Disassembly

WARNING: This page is about a different variant/trim than selected.
  1. Remove the transfer case. For additional information, refer to Transfer Case .
  2. Using the special tool, secure the transfer case to the bench.
    3. Fig 1: Securing Transfer Case To Bench
    GF0027619Courtesy of FORD MOTOR CO.
  3. If not previously done, remove the drain plug and drain the fluid.
    • When finished draining, install the drain plug and tighten to 20 N.m (15 lb-ft).
    4. Fig 2: Locating Drain Plug
    GF0004065Courtesy of FORD MOTOR CO.
  4. Using the special tool to hold the rear output flange, remove the rear output shaft flange nut.
    5. Fig 3: Locating Output Flange Nut And Special Tool (205-126)
    GF0027578Courtesy of FORD MOTOR CO.
  5. Remove the output shaft yoke washer.
  6. Using the special tool, remove the rear output shaft flange.
    7. Fig 4: Removing Rear Output Shaft Flange Using Special Tool (307-523)
    GF0027579Courtesy of FORD MOTOR CO.
  7. Remove and discard the output flange oil seal.
  8. Using the special tools, remove and discard the yoke-to-flange seal.
    9. Fig 5: Removing Rear Output Shaft Oil Seal Using Special Tools (100-001, 307-001)
    GF0027580Courtesy of FORD MOTOR CO.
  9. Remove the connector interlock from the electrical connector. Using an electrical connector pin extractor tool, remove the coil wire pin.
    10. Fig 6: Locating Coil Wire Electrical Connector
    GF0004138Courtesy of FORD MOTOR CO.
  10. Remove the 17 transfer case bolts.
    11. Fig 7: Locating Transfer Case Bolts
    GF0027620Courtesy of FORD MOTOR CO.
  11. Remove the 3 clutch coil assembly nuts.
    12. Fig 8: Locating Clutch Coil Assembly Nuts
    GF0027621Courtesy of FORD MOTOR CO.
  12. Separate the transfer case halves at the transfer case pry bosses.
    13. Fig 9: Separating Transfer Case Halves At Transfer Case Pry Bosses
    GF0027622Courtesy of FORD MOTOR CO.
  13. Remove the snap ring, then using the special tool, remove the rear output shaft support bearing.
    14. Fig 10: Locating Rear Output Shaft Support Bearing And Special Tool
    GF0027623Courtesy of FORD MOTOR CO.
  14. Using the special tool, remove the front output shaft rear bearing.
    15. Fig 11: Locating Front Output Shaft Rear Bearing And Special Tool
    GF0027624Courtesy of FORD MOTOR CO.
  15. Remove the thrust bearing.
    16. Fig 12: Locating Thrust Bearing
    GF0027625Courtesy of FORD MOTOR CO.
  16. Remove the cam and coil housing assembly.
    17. Fig 13: Locating Cam And Coil Housing Assembly
    GF0027626Courtesy of FORD MOTOR CO.
  17. Remove the apply cam and 3 steel balls.
  18. Remove the wave spring.
    19. Fig 14: Locating Steel Balls & Wave Spring
    GF0027627Courtesy of FORD MOTOR CO.
  19. Remove the snap ring.
    20. Fig 15: Locating Clutch Pack Assembly & Snap Ring
    GF0027628Courtesy of FORD MOTOR CO.
    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.
  20. Remove the clutch pack assembly.
  21. Remove the drive chain and the 2 sprockets as an assembly.
    22. Fig 16: Locating Drive Chain
    GF0027629Courtesy of FORD MOTOR CO.
  22. Remove and clean the oil pan magnet.
    23. Fig 17: Locating Oil Pan Magnet
    GF0027630Courtesy of FORD MOTOR CO.
  23. Remove the thrust washer.
    24. Fig 18: Locating Thrust Washer
    GF0027631Courtesy of FORD MOTOR CO.
  24. Remove the pump assembly and the rear output shaft as an assembly. Do not disassemble the pump assembly.
    25. Fig 19: Locating Rear Output Shaft
    GF0027632Courtesy of FORD MOTOR CO.
  25. Using the special tool, remove the oil seal.
    26. Fig 20: Removing Oil Seal Using Special Tool
    GF0027633Courtesy of FORD MOTOR CO.
  26. While holding the front output shaft and flange, remove the snap ring.
    27. Fig 21: Locating Snap Ring
    GF0027606Courtesy of FORD MOTOR CO.
  27. Remove the front output shaft and flange.
    28. Fig 22: Locating Front Output Shaft And Flange
    GF0027599Courtesy of FORD MOTOR CO.
  28. Using the special tools, remove the oil seal.
    29. Fig 23: Locating Oil Seal And Special Tools
    GF0027634Courtesy of FORD MOTOR CO.
  29. Using the special tools, remove the front output shaft support bearing.
    30. Fig 24: Locating Front Output Shaft Support Bearing And Special Tools
    GF0027635Courtesy of FORD MOTOR CO.
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