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Disassembly and Assembly

WARNING: This page is about a different variant/trim than selected.
    CAUTION: Discard all seals after removing them.
  1. Remove the transfer case from the vehicle. For additional information, refer to TRANSFER CASE .
    2. WARNING: Make sure the holding fixture lock pin is secure.
    Fig 1: Securing Transfer Case
    G01635545Courtesy of FORD MOTOR CO.
  2. Using the special tool, secure the transfer case to a bench.
  3. Remove the dampener.
  4. Remove the drain plug and drain the fluid, if not done previously.
    • Install the drain plug when finished draining.
      Fig 2: Locating Drain Plug
      G01635546Courtesy of FORD MOTOR CO.
  5. Index-mark the rear output flange and the upper output shaft.
    Fig 3: Index-Marking Rear Output Flange And Upper Output Shaft
    G01635547Courtesy of FORD MOTOR CO.
  6. Remove the components in the order indicated in the following illustration.
    Fig 4: Transfer Case Removal Sequence (1 Of 2)
    G01635548Courtesy of FORD MOTOR CO.
    Fig 5: Transfer Case Removal Sequence (2 Of 2)
    G01635549Courtesy of FORD MOTOR CO.
  7. To assemble, reverse the disassembly procedure.

Item 1: Output Flange Nut Disassembly Note 

  1. Using the special tool to hold the output flange, remove the nut.
    Fig 6: Removing Output Flange Nut
    G01635550Courtesy of FORD MOTOR CO.

Item 5: Output Flange Oil Seal Disassembly Note 

  1. Using the special tools, remove the oil seal.
    Fig 7: Removing Output Flange Oil Seal
    G01635551Courtesy of FORD MOTOR CO.

Item 8: Connector Interlock Disassembly Note 

  1. Remove the coil wire pin from the electrical connector.
    1. Remove the connector interlock.
    2. Remove the coil wire pin.
      • Use electrical connector pin extractor tool.
        Fig 8: Disassembling Connector Interlock
        G01635552Courtesy of FORD MOTOR CO.

Item 15: Transfer Case Cover Gear Disassembly Note 

  1. Separate the transfer case halves at the transfer case pry bosses.
    Fig 9: Disassembling Transfer Case Cover Gear
    G01635553Courtesy of FORD MOTOR CO.

Item 16: Front Output Shaft Rear Bearing Disassembly Note 

  1. Using the special tool, remove the bearing.
    Fig 10: Disassembling Front Output Shaft Rear Bearing
    G01635554Courtesy of FORD MOTOR CO.

Item 18: Rear Output Shaft Support Bearing Disassembly Note 

  1. Using the special tool, remove the bearing.
    Fig 11: Disassembling Rear Output Shaft Support Bearing
    G01635555Courtesy of FORD MOTOR CO.

Item 27: Clutch Pack Disassembly Note 

    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.
    Fig 12: Disassembling Clutch Pack
    G01635556Courtesy of FORD MOTOR CO.
  1. Remove the clutch pack.

Item 28: Drive Chain Disassembly Note 

  1. Remove the drive chain, driven sprocket and drive sprocket as an assembly.
    Fig 13: Disassembling Drive Chain
    G01635557Courtesy of FORD MOTOR CO.

Item 33: Rear Output Shaft Assembly Disassembly Note 

    CAUTION: Do not disassemble the pump assembly.
    Fig 14: Disassembling Rear Output Shaft Assembly
    G01635558Courtesy of FORD MOTOR CO.
  1. Remove the rear output shaft, pump assembly, and input shaft as an assembly.

Item 34: Input Shaft Oil Seal Disassembly Note 

  1. Using the special tool, remove the oil seal.
    Fig 15: Removing Input Shaft Oil Seal
    G01635559Courtesy of FORD MOTOR CO.

Item 35: Front Output Shaft Snap Ring Disassembly Note 

  1. Holding the front output shaft, remove the snap ring.
    Fig 16: Disassembling Front Output Shaft Snap Ring
    G01635560Courtesy of FORD MOTOR CO.

Item 37: Front Output Shaft Oil Seal Disassembly Note 

  1. Using the special tools, remove the oil seal.
    Fig 17: Removing Front Output Shaft Oil Seal
    G01635561Courtesy of FORD MOTOR CO.

Item 38: Front Output Shaft Support Bearing Disassembly Note 

  1. Using the special tools, remove the bearing.
    Fig 18: Removing Front Output Shaft Support Bearing
    G01635562Courtesy of FORD MOTOR CO.

Item 40: Input Shaft Support Bearing Disassembly Note 

  1. Using a suitable press and the special tool, remove the bearing.
    Fig 19: Removing Input Shaft Support Bearing
    G01635563Courtesy of FORD MOTOR CO.

Item 1: Output Flange Nut Assembly Note 

  1. Using the special tool to hold the rear output flange, install the nut.
    Fig 20: Installing Output Flange Nut
    G01635564Courtesy of FORD MOTOR CO.

Item 5: Output Flange Oil Seal Assembly Note 

  1. Using the special tool, install the seal.
    Fig 21: Installing Output Flange Oil Seal
    G01635565Courtesy of FORD MOTOR CO.

Item 13: Transfer Case Bolt Assembly Note 

  1. Install the bolts. Tighten them evenly in a star pattern.
    Fig 22: Tightening Transfer Case Bolts
    G01635566Courtesy of FORD MOTOR CO.

Item 15: Transfer Case Cover Assembly Note 

    CAUTION: Applying too much silicone sealant can plug the fluid filter and cause transfer case failure.
    NOTE: Make sure the transfer case mating surfaces are clean.
  1. Apply a 3-mm (1/8-inch) bead of sealant to the transfer case mating surfaces.

Item 16: Front Output Shaft Rear Bearing Assembly Note 

  1. Using the special tools, press the bearing into the case.
    Fig 23: Installing Front Output Shaft Rear Bearing
    G01635567Courtesy of FORD MOTOR CO.

Item 18: Rear Output Shaft Support Bearing Assembly Note 

  1. Using the special tools, press the bearing into the case.
    Fig 24: Installing Rear Output Shaft Support Bearing
    G01635568Courtesy of FORD MOTOR CO.

Item 27: Clutch Pack Assembly Note 

    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.
    Fig 25: Installing Clutch Pack Assembly
    G01635569Courtesy of FORD MOTOR CO.
  1. Install the clutch pack assembly.

Item 30: Drive Sprocket Assembly Note 

  1. Install the drive chain, driven sprocket and the drive sprocket as an assembly.
    Fig 26: Installing Drive Chain, Driven Sprocket And Drive Sprocket
    G01635570Courtesy of FORD MOTOR CO.

Item 33: Rear Output Shaft Assembly Note 

    CAUTION: Do not disassemble the pump assembly.
    Fig 27: Installing Rear Output Shaft, Pump Assembly, And Input Shaft
    G01635571Courtesy of FORD MOTOR CO.
  1. Install the rear output shaft, pump assembly, and input shaft as an assembly.

Item 34: Input Shaft Oil Seal Assembly Note 

  1. Using the special tool, install the oil seal.
    Fig 28: Installing Input Shaft Oil Seal
    G01635572Courtesy of FORD MOTOR CO.

Item 37: Front Output Shaft Oil Seal Assembly Note 

  1. Using the special tool, install the oil seal.
    Fig 29: Installing Front Output Shaft Oil Seal
    G01635573Courtesy of FORD MOTOR CO.

Item 38: Front Output Shaft Support Bearing Assembly Note 

  1. Using the special tools, press the bearing into the case.
    Fig 30: Installing Front Output Shaft Support Bearing
    G01635574Courtesy of FORD MOTOR CO.

Item 40: Input Shaft Support Bearing Assembly Note 

  1. Using a suitable press, install the bearing onto the input shaft.
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