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Transfer Case Disassembly

CAUTION: Discard all seals after removal.
NOTE: Refer to illustration for exploded view of transfer case assembly. See Fig 1.
Fig 1: Exploded View Of Transfer Case
G99B54016Courtesy of FORD MOTOR CO.
  1. Remove transfer case. See TRANSFER CASE REMOVAL & INSTALLATION . Remove rear output shaft lock nut, and discard. Remove rear output shaft flange and washer. Remove spacer.
  2. Using slide hammer (49 0223 630B) and seal remover (303-049 T92C-6700-CH) or equivalent, remove rear oil seal and sleeve. Remove transfer case shift motor. See ELECTRIC SHIFT MOTOR  under REMOVAL & INSTALLATION.
  3. Remove front bolts retaining rear case to front case. Remove rear bolts retaining front case to rear case. With front case facing downward, use a pry bar between the pry bosses to separate front case from rear case. See Fig 2.
    4. Fig 2: Identifying Pry Boss Location
    G00386712Courtesy of MAZDA MOTORS CORP.
  4. Place rear case on workbench. Remove all traces of old sealant from case mating surfaces. Remove output shaft bearing snap ring. See Fig 3. Using driver handle and puller, remove rear output shaft bearing from rear case.
    5. Fig 3: Identifying Output Shaft Bearing Snap Ring
    G00386713Courtesy of MAZDA MOTORS CORP.
  5. From outside of case, drive out rear output shaft bearing using a drift and Bearing Remover (49 H033 101) or equivalent. See Fig 4. Using Impact Slide Hammer (49 0223 630B and Collet (49 UN01 022) or equivalent, remove front output shaft needle bearing. See Fig 5.
    6. Fig 4: Removing Rear Output Shaft Bearing
    G00386714Courtesy of MAZDA MOTORS CORP.
    Fig 5: Identifying Front Output Shaft Needle Bearing
    G00386715Courtesy of MAZDA MOTORS CORP.
  6. Remove clutch coil nyloc nuts, and pull clutch coil assembly with "O" rings and Brown wire from rear case. See Fig 6.
    Fig 6: Identifying Nyloc Nuts
    G00386716Courtesy of MAZDA MOTORS CORP.
  7. Remove lock-up return spring from fork boss. See Fig 7. Remove clutch coil housing from output shaft. See Fig 8.
    8. Fig 7: Identifying Boss Spring
    G00386717Courtesy of MAZDA MOTORS CORP.
    Fig 8: Removing Clutch Housing From Output Shaft
    G00386718Courtesy of MAZDA MOTORS CORP.
  8. Remove 2WD-4WD lock-up assembly and shift fork as an assembly from output shaft. See Fig 9.
    9. Fig 9: Removing Lock-Up Assembly & Drive Chain
    G94A39156Courtesy of FORD MOTOR CO.
  9. Pull out shift rail. Remove internal snap ring. See Fig 10. Pull lock-up hub and sleeve return spring from 2WD-4WD lock-up assembly. See Fig 11.
    10. Fig 10: Identifying Internal Snap Ring
    G00386721Courtesy of MAZDA MOTORS CORP.
    Fig 11: Identifying 2W-4W Lockup Hub, Sleeve & Spring
    G00386720Courtesy of MAZDA MOTORS CORP.
  10. Remove shift cam assembly from transfer case. See Fig 12. Remove external snap ring and thrust washer that retains driven sprocket to front output shaft. Remove chain, driven sprocket and drive sprocket as an assembly. See Fig 9.
    11. Fig 12: Identifying Shift Cam Assembly
    G00386719Courtesy of MAZDA MOTORS CORP.
  11. Remove oil sump magnet from slot in front of case bottom. See Fig 13. Remove rear output shaft and oil pump as an assembly. See Fig 14.
    12. Fig 13: Removing/Installing Magnet From Case Bottom
    G00386722Courtesy of MAZDA MOTORS CORP.
    Fig 14: Removing/Installing Rear Output Shaft & Oil Pump Assembly
    G00386723Courtesy of MAZDA MOTORS CORP.
    CAUTION: DO NOT use force or hammer on oil pump to remove. If resistance is encountered, start procedure over.
  12. Rotate pump to align cover keyway with oil pump drive pin in output shaft, and pull pump assembly off of output shaft. See Fig 15. For reassembly purposes, measure and record oil pump drive pin height in output shaft. See Fig 16. Remove oil pump drive pin from output shaft.
    13. Fig 15: Aligning Cover Key Way
    G00386724Courtesy of MAZDA MOTORS CORP.
    Fig 16: Identifying Oil Pump Drive Pin
    G00386725Courtesy of MAZDA MOTORS CORP.
  13. Remove front output shaft retaining snap ring. See Fig 9. Remove front output shaft. Remove High-Low (H-L) shift fork and collar as an assembly. See Fig 17.
    14. Fig 17: Removing H-L Shift Fork & Hub
    G00386726Courtesy of MAZDA MOTORS CORP.
  14. Turn front case over. Remove 6 bolts, main drive gear bearing retainer, input shaft and front planet as an assembly from front case. Using snap ring pliers, expand tangs of large snap ring in main drive gear bearing retainer, and remove main drive gear assembly from bearing. See Fig 18.
    Fig 18: Exploded View Of Main Drive Gear Bearing Retainer Assembly
    G94B39181Courtesy of FORD MOTOR CO.
  15. Using a Slide Hammer (49 0223 630B) and Seal Remover (303-049 T92C-6700-C) or equivalent, remove input oil seal from front adapter. See Fig 19.
    16. Fig 19: Identifying Input Oil Seal
    G00386727Courtesy of MAZDA MOTORS CORP.
  16. Remove snap ring retaining bearing to the input shaft, and remove input shaft from front planet assembly and bearing. See Fig 20. Remove snap ring, thrust washer, thrust plate and sun gear from main drive gear assembly. See Fig 21.
    17. Fig 20: Removing Input Shaft From Planetary Carrier
    G00386728Courtesy of MAZDA MOTORS CORP.
    Fig 21: Identifying Internal Snap Ring, Thrust Washer & Sun Gear
    G00386729Courtesy of MAZDA MOTORS CORP.
  17. Using a press, position input shaft and Axle Bearing/Seal Plate (49 H027 002) and pinion Bearing Cone Replacer (49 UN01 036) or equivalent, Insert Input Shaft Bearing Remover (49 UN01 124) into input shaft. Tighten actuator pin until it stops. Press needle bearing and sleeve out of input shaft together. See Fig 22.
    18. Fig 22: Removing/Installing Bearing & Sleeve
    G00386730Courtesy of MAZDA MOTORS CORP.
  18. Using a press, remove ring gear from front case. See Fig 23. Remove front output shaft bearing internal snap ring, and remove bearing from front case. Using Impact Slide Hammer (49 0223 630B) or equivalent, remove front output yoke-to-flange seal from front case.
    19. Fig 23: Removing/Installing Ring Gear From Transfer Case
    G00386731Courtesy of MAZDA MOTORS CORP.
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