Transfer Case: Disassembly

Transfer Case Disassembled View 

Fig 1: Exploded View Of Transfer Case

Courtesy of FORD MOTOR CO.

1. Remove the transfer case from the vehicle. For additional information, refer to TRANSFER CASE .
2. Attach the transfer case to the Transmission Holding Fixture.
   Fig 2: Attaching Transfer Case To Transmission Holding Fixture

   Courtesy of FORD MOTOR CO.
NOTE: Index-mark the rear output shaft and the flange.
NOTE: The nut has a self-locking feature. Discard the nut and the washer after removing.
Fig 3: Locating Flange Nut And Washer
Courtesy of FORD MOTOR CO.
3. Use the Drive Pinion Flange Holding Fixture to prevent the flange from turning. Remove and discard the flange nut and the washer.
4. Using a suitable puller and the Drive Pinion Flange Holding Fixture, remove the flange.
   Fig 4: Driving Pinion Flange Holding Fixture

   Courtesy of FORD MOTOR CO.
5. Remove and discard the oil seal if it remains on the rear output shaft.
   Fig 5: Locating Oil Seal On Rear Output Shaft

   Courtesy of FORD MOTOR CO.
6. Using the Oil Seal Remover, remove and discard the rear output shaft seal.
   Fig 6: Removing Rear Output Shaft Seal

   Courtesy of FORD MOTOR CO.
7. Remove the spacer.
   Fig 7: Locating Spacer

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8. Remove the shift motor bracket bolt and the 3 shift motor bolts.
   Fig 8: Locating Shift Motor Bracket Bolt And Shift Motor Bolts

   Courtesy of FORD MOTOR CO.
9. Remove the coil wire from the shift motor electrical connector.
   1. Remove the inner retainer from the electrical connector.
   2. Lift up on the lock tab and remove the wire from the electrical connector.
   Fig 9: Identifying Inner Retainer From Electrical Connector

   Courtesy of FORD MOTOR CO.
10. Remove the 9 transfer case cover bolts.
    Fig 10: Locating Transfer Case Cover Bolts

    Courtesy of FORD MOTOR CO.
NOTE: Position the assembly so that the front of the transfer case is facing downward.
Fig 11: Separating Transfer Case Cover From Transfer Case
Courtesy of FORD MOTOR CO.
11. Using the pry bosses, separate the transfer case cover from the transfer case.
12. Remove the snap ring that retains the bearing in the case.
    Fig 12: Locating Snap Ring

    Courtesy of FORD MOTOR CO.
13. Using the Stator Bearing Remover with the Slide Hammer, remove the bearing.
    Fig 13: Removing Stator Bearing

    Courtesy of FORD MOTOR CO.
14. Using the Collet with the Slide Hammer, remove the needle bearing.
    Fig 14: Removing Needle Bearing

    Courtesy of FORD MOTOR CO.
15. Remove the following:
    1. Shift collar hub.
    2. Return spring.
    3. Lockup collar and the lockup fork as an assembly.
    4. Electric shift cam assembly.
    5. Shift rail.
    Fig 15: Identifying Shift Collar Hub And Return Spring

    Courtesy of FORD MOTOR CO.
16. Remove the lockup hub snap ring.
    Fig 16: Locating Lockup Hub Snap Ring

    Courtesy of FORD MOTOR CO.
17. Remove the lockup hub and the sleeve return spring from the lockup collar.
    Fig 17: Locating Lockup Hub And Sleeve Return Spring From Lockup Collar

    Courtesy of FORD MOTOR CO.
18. Remove the snap ring and the spacer.
    Fig 18: Locating Snap Ring And Spacer

    Courtesy of FORD MOTOR CO.
19. Remove the drive chain, driven sprocket, and the drive sprocket as an assembly.
    Fig 19: Removing Drive Chain And Driven Sprocket

    Courtesy of FORD MOTOR CO.
20. Remove the magnet and the oil strainer from the slot in the transfer case.
    Fig 20: Locating Magnet And Oil Strainer From Slot In Transfer Case

    Courtesy of FORD MOTOR CO.
21. Remove the rear output shaft and the pump assembly as an assembly.
    Fig 21: Locating Rear Output Shaft And Pump Assembly

    Courtesy of FORD MOTOR CO.
22. Rotate the pump assembly to align the keyway in the cover and the spring pin in the rear output shaft and separate the pump from the shaft.
    Fig 22: Locating Pump Assembly To Keyway In Cover And Spring Pin

    Courtesy of FORD MOTOR CO.
NOTE: The height of the oil pump spring pin must be measured before removal so that during assembly, it can be installed at the correct height so that the oil pump shaft rotates with the rear output shaft.
Fig 23: Measuring Pump Drive Pin Height Diameter Of Rear Output Shaft
Courtesy of FORD MOTOR CO.
23. Using a micrometer, measure and record the pump drive pin height above the diameter of the rear output shaft. Remove the drive pin from the rear output shaft.
NOTE: Do not let the front output shaft assembly fall out of the case while removing the snap ring or damage to the component may occur.
Fig 24: Locating Snap Ring
Courtesy of FORD MOTOR CO.
24. Remove the snap ring. Discard the snap ring if it was damaged during removal.
25. Remove the front output shaft.
    Fig 25: Removing Front Output Shaft

    Courtesy of FORD MOTOR CO.
26. Remove the reduction fork and the reduction hub as an assembly.
    Fig 26: Removing Reduction Fork And Reduction Hub Assembly

    Courtesy of FORD MOTOR CO.
27. Remove the 6 bolts retaining the front adapter to the case.
    Fig 27: Locating Bolts Retaining Front Adapter To Case

    Courtesy of FORD MOTOR CO.
28. Remove the front adapter, input shaft and the complete carrier as an assembly.
    Fig 28: Removing Front Adapter, Input Shaft And Complete Carrier Assembly

    Courtesy of FORD MOTOR CO.
29. Using snap ring pliers, expand the tangs of the large snap ring and remove the complete carrier and the input shaft from the front adapter.
    Fig 29: Removing Complete Carrier And Input Shaft From Front Adapter

    Courtesy of FORD MOTOR CO.
30. Remove the large snap ring from the front adapter.
    Fig 30: Locating Large Snap Ring From Front Adapter

    Courtesy of FORD MOTOR CO.
31. Using a suitable tool, remove and discard the oil seal from the front adapter.
    Fig 31: Locating Oil Seal From Front Adapter

    Courtesy of FORD MOTOR CO.
32. Remove the snap ring retaining the input shaft to the planet carrier.
    Fig 32: Locating Snap Ring Retaining Input Shaft To Planet Carrier

    Courtesy of FORD MOTOR CO.
33. Using the Bearing Puller and a suitable press, remove the bearing.
    Fig 33: Locating Bearing

    Courtesy of FORD MOTOR CO.
34. Remove the thrust washer and the input shaft.
    Fig 34: Locating Thrust Washer And Input Shaft

    Courtesy of FORD MOTOR CO.
35. Remove the snap ring, the thrust plate and the sun gear.
    Fig 35: Locating Snap Ring, Thrust Plate And Sun Gear

    Courtesy of FORD MOTOR CO.
NOTE: Remove and discard both the sleeve bearing and the needle bearing if either one is worn/damaged.
Fig 36: Removing Needle Bearing And Sleeve Bearing From Input Shaft
Courtesy of FORD MOTOR CO.
36. Using the Input Shaft Bearing Remover, Shaft Bearing Cone Installer, Bearing Oil Seal Plate and a suitable press, remove the needle bearing and the sleeve bearing from the input shaft.
37. Using a suitable tool, remove and discard the oil seal.
    Fig 37: Locating Oil Seal

    Courtesy of FORD MOTOR CO.
38. Remove the snap ring retaining the bearing to the case.
    Fig 38: Locating Snap Ring Retaining Bearing To Case

    Courtesy of FORD MOTOR CO.
39. Using the Stator Bearing Remover with the Slide Hammer, remove the bearing.
    Fig 39: Locating Stator Bearing

    Courtesy of FORD MOTOR CO.
40. Using a suitable tool, remove and discard the oil seal.
    Fig 40: Locating Oil Seal

    Courtesy of FORD MOTOR CO.
41. Remove the shift fork facings.
    Fig 41: Locating Shift Fork Facings

    Courtesy of FORD MOTOR CO.
42. Remove the electric shift cam from the shift shaft.
    Fig 42: Locating Electric Shift Cam From Shift Shaft

    Courtesy of FORD MOTOR CO.
43. WARNING: Keep fingers away from spring ends when releasing the spring. Spring ends are under tension and will unwind with force. Failure to follow this instruction may result in injured fingers.

Remove the torsion spring and the spacer from the shift shaft.

Fig 43: Locating Torsion Spring And Spacer From Shift Shaft

Courtesy of FORD MOTOR CO.