Transfer Case - Navigator: Disassembly

WARNING: This page is about a different variant/trim than selected.

NOTE: Use a suitable cleaning 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.

Clean the transfer case exterior with solvent and dry with compressed air.
Using the Transmission Holding Fixture, secure the transfer case to a work bench. Rotate the transfer case so that the output shaft is pointing upward.

Fig 1: Removing Transfer Case From Transmission Holding Fixture
Courtesy of FORD MOTOR CO.
Drain the fluid from the transfer case, if not done previously.

Fig 2: Locating Drain Fluid From Transfer Case
Courtesy of FORD MOTOR CO.
Using a suitable tool, remove and discard the rear output shaft seal.

Fig 3: Removing Rear Output Shaft Seal
Courtesy of FORD MOTOR CO.
Remove the inner connector retainer. Press the release tab and remove the coil wire pin (blue wire).

Fig 4: Locating Inner Connector Retainer
Courtesy of FORD MOTOR CO.
Remove the 2 connector bracket bolts and the connector bracket.

Fig 5: Locating Connector Bracket Bolts
Courtesy of FORD MOTOR CO.
Remove the 3 coil nuts and washers.

Fig 6: Locating Coil Nuts And Washers
Courtesy of FORD MOTOR CO.

NOTE: It is normal to find metal shavings after removing the self-tapping transfer case bolts.

Fig 7: Locating Transfer Case Cover Bolts

Courtesy of FORD MOTOR CO.

Remove the 20 transfer case bolts.
Using the pry bosses, separate the transfer case halves.

Fig 8: Separating Transfer Case Halves
Courtesy of FORD MOTOR CO.
Using the Bearing Cup Remover with the Slide Hammer, remove the rear output shaft support bearing.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
  
  Fig 9: Removing Rear Output Shaft Support Bearing
  Courtesy of FORD MOTOR CO.
Using the Bearing Cup Remover with the Slide Hammer, remove the front output shaft rear bearing.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
  
  Fig 10: Removing Front Output Shaft Rear Bearing
  Courtesy of FORD MOTOR CO.
Remove the snap ring.
- Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
  
  Fig 11: Locating Snap Ring
  Courtesy of FORD MOTOR CO.
Remove the spacer.

Fig 12: Locating Snap Ring And Spacer
Courtesy of FORD MOTOR CO.
Remove the caged thrust bearing assembly.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
  
  Fig 13: Locating Caged Thrust Bearing Assembly
  Courtesy of FORD MOTOR CO.
Remove the cam/coil housing.

Fig 14: Locating Cam/Coil Housing
Courtesy of FORD MOTOR CO.
Remove the 3 steel balls and the cam.

Fig 15: Locating Steel Balls And Cam
Courtesy of FORD MOTOR CO.
Remove the wave spring.

Fig 16: Locating Wave Spring
Courtesy of FORD MOTOR CO.
Remove and discard the snap ring.

Fig 17: Locating Snap Ring
Courtesy of FORD MOTOR CO.

NOTE: 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.

Fig 18: Locating Clutch Pack Assembly

Courtesy of FORD MOTOR CO.

Remove the clutch pack assembly.
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.
  
  Fig 19: Locating Drive Chain And Sprockets Assembly
  Courtesy of FORD MOTOR CO.
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.
  - Inspect the washers and bearing for wear or damage. Install new components as necessary.
    
    Fig 20: Identifying Thrust Bearing Assembly
    Courtesy of FORD MOTOR CO.
Remove and clean the oil pan magnet.

Fig 21: Locating Oil Pan Magnet
Courtesy of FORD MOTOR CO.
Remove the oil pump assembly.

Fig 22: Locating Oil Pump Assembly
Courtesy of FORD MOTOR CO.
Remove the output shaft.

Fig 23: Locating Output Shaft
Courtesy of FORD MOTOR CO.
Remove the input shaft.

Fig 24: Locating Input Shaft
Courtesy of FORD MOTOR CO.

NOTE: Do not let the front output shaft fall when removing the snap ring.

Remove the snap ring and the front output shaft.
- Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
  
  Fig 25: Locating Snap Ring And Front Output Shaft
  Courtesy of FORD MOTOR CO.

NOTE: Carefully remove the seal, do not damage the seal bore.

Fig 26: Locating Front Output Shaft Oil Seal

Courtesy of FORD MOTOR CO.

Remove and discard the front output shaft oil seal.

NOTE: Carefully remove the seal, do not damage the seal bore.

Fig 27: Locating Front Input Shaft Seal

Courtesy of FORD MOTOR CO.

Remove and discard the front input shaft seal.
Using a suitable driver, remove the front input shaft bearing.

Fig 28: Removing Front Input Shaft Bearing
Courtesy of FORD MOTOR CO.
Using a suitable driver, remove the front output shaft support bearing.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
  
  Fig 29: Removing Front Output Shaft Support Bearing
  Courtesy of FORD MOTOR CO.