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Transfer Case: Disassembly

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

CAUTION: Discard all nuts, bolts, and retaining rings after removing them from the transfer case. Install all new fasteners during transfer case assembly.

All transfer cases

Attach the transfer case to the special tool.

Fig 1: Attaching Transfer Case To Special Tool
Courtesy of FORD MOTOR CO.

Electric shift transfer case

Remove the gearmotor encoder assembly.

Fig 2: Removing Gearmotor Encoder Assembly
Courtesy of FORD MOTOR CO.

Manual shift transfer case

Remove the 3 position switch.

Fig 3: Removing Position Switch
Courtesy of FORD MOTOR CO.

All transfer cases

CAUTION: Do not use air tools to remove the plugs.

Fig 4: Removing Drain Plugs

G03909695

Courtesy of FORD MOTOR CO.

Remove the drain and fill plugs.
Remove and discard the nut.
- Use the special tool to prevent the flange from turning.
Fig 5: Removing Nut
Courtesy of FORD MOTOR CO.
Using a suitable 2- or 3-jaw puller, remove the flange.

Fig 6: Removing Flange
Courtesy of FORD MOTOR CO.
Remove and discard the nut.
- Use the special tool to prevent the flange from turning.
Fig 7: Removing Nut
Courtesy of FORD MOTOR CO.
Using a suitable 2- or 3-jaw puller, remove the flange.

Fig 8: Removing Flange
Courtesy of FORD MOTOR CO.
Remove the slinger from the front flange and the rear flange, if necessary.

Fig 9: Removing Slinger From Front Flange And Rear Flange
Courtesy of FORD MOTOR CO.
Using the special tools, remove the rear output seal.

Fig 10: Removing Rear Output Seal
Courtesy of FORD MOTOR CO.
Remove and discard the eight bolts retaining the rear retainer to the rear case.

Fig 11: Removing Bolts Retaining Rear Retainer To Rear Case
Courtesy of FORD MOTOR CO.
Remove the rear retainer.
- Use the special tool to separate the rear retainer from the rear case.
Fig 12: Removing Rear Retainer From Rear Case
Courtesy of FORD MOTOR CO.
Using the special tools and a suitable press, remove the needle bearing.

Fig 13: Removing Needle Bearing
Courtesy of FORD MOTOR CO.
Disconnect the oil tube and remove the oil pump assembly.

Fig 14: Removing Oil Pump Assembly
Courtesy of FORD MOTOR CO.
Remove and discard the retaining ring.
1. Install the special tool.
2. Lift up on the shaft, and remove and discard the retaining ring.
  - Remove the special tool.
Fig 15: Removing Retaining Ring
Courtesy of FORD MOTOR CO.
Remove and discard the 25 bolts retaining the rear case to the front case.

Fig 16: Removing Bolts Retaining Rear Case To Front Case
Courtesy of FORD MOTOR CO.
Remove the rear case.
- Use the special tool to separate the case halves.
Fig 17: Removing Rear Case
Courtesy of FORD MOTOR CO.
Remove the oil tube.

Fig 18: Removing Oil Tube
Courtesy of FORD MOTOR CO.
Remove the ball bearing retaining ring.

Fig 19: Removing Ball Bearing Retaining Ring
Courtesy of FORD MOTOR CO.
Using the special tools and a suitable press, remove the ball bearing.

Fig 20: Removing Ball Bearing
Courtesy of FORD MOTOR CO.
Using the special tool, remove the needle bearing.

Fig 21: Removing Needle Bearing
Courtesy of FORD MOTOR CO.
Remove the chip collector magnet.

Fig 22: Removing Chip Collector Magnet
Courtesy of FORD MOTOR CO.
Remove the driven sprocket retaining ring.

Fig 23: Removing Driven Sprocket Retaining Ring
Courtesy of FORD MOTOR CO.
Remove the drive sprocket retaining ring.

Fig 24: Removing Drive Sprocket Retaining Ring
Courtesy of FORD MOTOR CO.
Remove the mode spring.

Fig 25: Removing Mode Spring
Courtesy of FORD MOTOR CO.
Remove the sprockets and chain as an assembly.

Fig 26: Removing Sprockets And Chain
Courtesy of FORD MOTOR CO.
Remove the mainshaft and the mode fork assembly as an assembly.

Fig 27: Removing Mainshaft And Mode Fork Assembly
Courtesy of FORD MOTOR CO.
Slide the mode fork and synchronizer sleeve off the mainshaft, and separate the components.
- Mode sleeve for mechanical shift or synchronizer sleeve for electric shift.
Fig 28: [Sliding Mode Fork And Synchronizer Sleeve]
Courtesy of FORD MOTOR CO.
Place the mainshaft in a soft jawed vise with the threaded end upward.
Remove the clutch gear.

Fig 29: Removing Clutch Gear
Courtesy of FORD MOTOR CO.

Mechanical shift transfer case

Remove the mode hub.

Electric shift transfer case

Remove the retaining ring and the synchronizer hub.

Fig 30: Removing Retaining Ring And Synchronizer Hub
Courtesy of FORD MOTOR CO.
Remove the outer ring.

Fig 31: Removing Outer Ring
Courtesy of FORD MOTOR CO.
Remove the middle ring.

Fig 32: Removing Middle Ring
Courtesy of FORD MOTOR CO.
Remove the inner ring.

Fig 33: Removing Inner Ring
Courtesy of FORD MOTOR CO.

All transfer cases

Remove the drive sprocket hub.

Fig 34: Removing Drive Sprocket Hub
Courtesy of FORD MOTOR CO.
Inspect all of the components for wear and damage.
Inspect the mode fork pads for wear.

Fig 35: Identifying Mode Fork Pads
Courtesy of FORD MOTOR CO.

NOTE: Manual shift range fork shown, electric shift range fork similar.

NOTE: Rotate the sector assembly to the 4-wheel high position for easy removal.

Fig 36: Removing Range Fork Assembly And Range Shift Sleeve

G03909727

Courtesy of FORD MOTOR CO.

Remove the range fork assembly and the range shift sleeve.

NOTE: Manual shift range fork shown, electric shift range fork similar.

Fig 37: Identifying Range Fork Pads

G03909728

Courtesy of FORD MOTOR CO.

Inspect the range fork pads for wear. If the pads are worn, discard the range fork, the pads, the mainshaft, and the sleeve.
Using the special tools, remove the input seal.

Fig 38: Removing Input Seal
Courtesy of FORD MOTOR CO.
Remove and discard the retaining ring.
1. Install the special tool.
2. Remove and discard the retaining ring.
  - Remove the special tool.
Fig 39: Removing Retaining Ring
Courtesy of FORD MOTOR CO.
Remove the planetary assembly.

Fig 40: Removing Planetary Assembly
Courtesy of FORD MOTOR CO.
Remove the input bearing retaining ring.

Fig 41: Removing Input Bearing Retaining Ring
Courtesy of FORD MOTOR CO.
Using the special tool and a suitable press, remove the front input bearing.

Fig 42: Removing Front Input Bearing
Courtesy of FORD MOTOR CO.
Using the special tools, remove the front output seal.

Fig 43: Removing Front Output Seal
Courtesy of FORD MOTOR CO.
Remove and discard the retaining ring.
1. Install the special tool.
2. Remove and discard the retaining ring.
Fig 44: Removing Retaining Ring
Courtesy of FORD MOTOR CO.
Remove the special tool and the front output shaft.

Fig 45: Removing Front Output Shaft
Courtesy of FORD MOTOR CO.
Remove the front output ball bearing retaining ring.

Fig 46: Removing Front Output Ball Bearing Retaining Ring
Courtesy of FORD MOTOR CO.
Using the special tools and a suitable press, remove the front output ball bearing.

Fig 47: Removing Front Output Ball Bearing
Courtesy of FORD MOTOR CO.
Remove the lock plate retaining ring.

Fig 48: Removing Lock Plate Retaining Ring
Courtesy of FORD MOTOR CO.
Lift out the input gear.
- Inspect the input gear for wear or damage. Install a new gear if necessary.
Fig 49: Removing Input Gear
Courtesy of FORD MOTOR CO.
Remove the lock plate.

Fig 50: Removing Lock Plate
Courtesy of FORD MOTOR CO.
Remove the front input gear thrust washer.

Fig 51: Removing Front Input Gear Thrust Washer
Courtesy of FORD MOTOR CO.
Remove the rear input gear thrust washer.

Fig 52: Removing Rear Input Gear Thrust Washer
Courtesy of FORD MOTOR CO.
Inspect the gear teeth and thrust washers for wear and damage. Discard the planetary gear assembly, if necessary.

Fig 53: Identifying Gear Teeth And Thrust Washers
Courtesy of FORD MOTOR CO.
Remove the poppet assembly.

Fig 54: Removing Poppet Assembly
Courtesy of FORD MOTOR CO.

NOTE: If installing a new poppet spring, it must be like in color to the original poppet spring.

Fig 55: Disassembling Spring And Poppet

G03923948

Courtesy of FORD MOTOR CO.

Disassemble the poppet screw, the spring, and the poppet.

Manual shift transfer case

Remove the locknut, the washer, the lever, the spacer, and the sector assembly.

Fig 56: Removing Lever, Spacer And Sector Assembly (Manual Shift Transfer Case)
Courtesy of FORD MOTOR CO.

Electric shift transfer case

Remove the plastic retainer and the O-ring, and remove the sector assembly.

Fig 57: Removing Sector Assembly (Electric Shift Transfer Case)
Courtesy of FORD MOTOR CO.

All transfer cases

Using the special tool, remove the sector shaft support (motor adapter for electric shift transfer case).

Fig 58: Removing Sector Shaft Support
Courtesy of FORD MOTOR CO.
Remove and discard the support O-ring seal.

Fig 59: Removing Support O-Ring Seal
Courtesy of FORD MOTOR CO.