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Transfer Case: Disassembly

    WARNING: Make sure protective eyewear is in place.
    WARNING: Use a petroleum-based solvent to clean the transfer case. Refer to the solvent manufacturer's safety precautions to prevent personal injury or transfer case damage.
    CAUTION: Seal all openings before cleaning the transfer case exterior. This will prevent entry of dirt and water, which can cause damage to internal components.
  1. Clean the transfer case exterior with solvent and dry with compressed air.
  2. Using the special tool, secure the transfer case to a work bench. Rotate the transfer case so that the output shaft is pointing upward.
    Fig 1: Securing Transfer Case To Work Bench
    G01565377Courtesy of FORD MOTOR CO.
  3. Drain the fluid from the transfer case, if not done previously.
  4. Using a suitable tool, remove and discard the oil seal.
    Fig 2: Removing And Discarding Oil Seal
    G01565378Courtesy of FORD MOTOR CO.
  5. Remove the coil wire pin from the electrical connector.
    1. Remove the wire connector spacer.
    2. Remove the coil wire pin (tan wire).
      • Use an electrical connector pin extractor tool.
        Fig 3: Removing Coil Wire Pin From Electrical Connector
        G01565379Courtesy of FORD MOTOR CO.
  6. Remove the bolts and transfer case shift motor.
    Fig 4: Removing Bolts And Transfer Case Shift Motor
    G01565380Courtesy of FORD MOTOR CO.
  7. Remove the three coil nuts and washers.
    Fig 5: Removing Coil Nuts And Washers
    G01565381Courtesy of FORD MOTOR CO.
    8. NOTE: It is normal to find metal shavings after removing the self-tapping transfer case bolts.
    Fig 6: Removing Transfer Case Bolts
    G01565382Courtesy of FORD MOTOR CO.
  8. Remove the 20 bolts.
  9. Separate the transfer case halves.
    • Use the pry bosses to separate the case halves.
      Fig 7: Separating Transfer Case Halves (1 Of 2)
      G01565383Courtesy of FORD MOTOR CO.
      Fig 8: Separating Transfer Case Halves (2 Of 2)
      G01565384Courtesy of FORD MOTOR CO.
  10. Using the special tools, remove the rear output shaft support bearing.
    Fig 9: Removing Rear Output Shaft Support Bearing
    G01565385Courtesy of FORD MOTOR CO.
  11. Using the special tools, remove the front output shaft rear bearing.
    Fig 10: Removing Front Output Shaft Rear Bearing
    G01565386Courtesy of FORD MOTOR CO.
  12. Remove the snap ring.
    • Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
      Fig 11: Removing Snap Ring
      G01565387Courtesy of FORD MOTOR CO.
  13. Remove the caged thrust bearing assembly.
    • Inspect the bearing for wear or damage. Install a new bearing as necessary.
      Fig 12: Removing Caged Thrust Bearing Assembly
      G01565388Courtesy of FORD MOTOR CO.
  14. Remove the cam/coil housing.
    Fig 13: Removing Cam/Coil Housing
    G01565389Courtesy of FORD MOTOR CO.
  15. Remove the steel balls and the cam.
    Fig 14: Removing Y
    G01565390Courtesy of FORD MOTOR CO.
  16. Remove the wave spring.
    Fig 15: Removing Wave Spring
    G01565391Courtesy of FORD MOTOR CO.
  17. Remove and discard the snap ring.
    Fig 16: Removing And Discarding Snap Ring
    G01565392Courtesy of FORD MOTOR CO.
  18. Remove the lockup shift fork spring.
    Fig 17: Removing Lockup Shift Fork Spring
    G01565393Courtesy of FORD MOTOR CO.
    19. CAUTION: When removing 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 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 18: Removing Clutch Pack Assembly
    G01565394Courtesy of FORD MOTOR CO.
  19. Remove the clutch pack assembly.
  20. 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: Removing Drive Chain And Sprockets
      G01565395Courtesy of FORD MOTOR CO.
  21. 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: Removing Thrust Bearing Assembly
      G01565396Courtesy of FORD MOTOR CO.
  22. Remove the lockup collar and the lockup fork as an assembly.
    • Separate and inspect the lockup collar and the lockup fork for wear or damage.
      Fig 21: Removing Lockup Collar And Lockup Fork
      G01565397Courtesy of FORD MOTOR CO.
  23. Remove and clean the oil pan magnet.
    Fig 22: Removing Oil Pan Magnet
    G01565398Courtesy of FORD MOTOR CO.
  24. Remove the output shaft hub.
    Fig 23: Removing Output Shaft Hub
    G01565399Courtesy of FORD MOTOR CO.
  25. Remove the oil pump assembly.
    Fig 24: Removing Oil Pump Assembly
    G01565400Courtesy of FORD MOTOR CO.
  26. Remove the output shaft.
    Fig 25: Removing Output Shaft
    G01565401Courtesy of FORD MOTOR CO.
    27. WARNING: Do not disassemble the shift cam assembly.
  27. Remove the reduction shift fork, the reduction hub, and the shift cam as an assembly.
    • Separate and inspect the reduction hub and the reduction shift fork for wear or damage.
      Fig 26: Removing Reduction Shift Fork, Reduction Hub, And Shift Cam
      G01565402Courtesy of FORD MOTOR CO.
  28. Remove the shift fork shaft.
    Fig 27: Removing Shift Fork Shaft
    G01565403Courtesy of FORD MOTOR CO.
  29. Remove the front planet.
    • Using a drift and a hammer, remove the front planet needle bearing, if necessary.
      Fig 28: Removing Front Planet Needle Bearing
      G01565404Courtesy of FORD MOTOR CO.
  30. Remove the ring gear.
    1. Remove the snap ring.
      1. Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
    2. Remove the ring gear.
      Fig 29: Removing Ring Gear
      G01565405Courtesy of FORD MOTOR CO.
    31. CAUTION: Do not let the front output shaft fall when removing the snap ring.
  31. 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 30: Installing Snap Ring
      G01565406Courtesy of FORD MOTOR CO.
    32. NOTE: Carefully remove the seal, do not damage the seal bore.
    Fig 31: Removing And Discarding Front Output Shaft Oil Seal
    G01565407Courtesy of FORD MOTOR CO.
  32. Remove and discard the front output shaft oil seal.
    33. NOTE: Carefully remove the seal, do not damage the seal bore.
    Fig 32: Removing And Discarding Front Input Shaft Oil Seal
    G01565408Courtesy of FORD MOTOR CO.
  33. Remove and discard the front input shaft oil seal.
  34. Using a suitable driver, remove the front planet support bearing.
    Fig 33: Removing Front Planet Support Bearing
    G01565409Courtesy of FORD MOTOR CO.
  35. Using a suitable driver, remove the front output shaft support bearing.
    Fig 34: Removing Front Output Shaft Support Bearing
    G01565410Courtesy of FORD MOTOR CO.
  36. Using a suitable tool, remove and discard the shifter shaft seal.
    Fig 35: Removing And Discarding Shifter Shaft Seal
    G01565411Courtesy of FORD MOTOR CO.
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