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Transfer Case: Disassembly

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    CAUTION: Use a petroleum-based solvent to clean the transfer case. Seal all openings before cleaning the transfer case exterior. This will prevent entry of dirt and water, which may 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.
    3. Fig 1: Securing Transfer Case To Bench
    GF0004137Courtesy 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 rear output shaft seal.
    5. Fig 2: Removing Transfer Case Rear Output Shaft Seal
    GF0004050Courtesy of FORD MOTOR CO.
  5. Remove the coil wire pin from the electrical connector.
    • Remove the wire connector spacer.
    • Using an electrical connector pin extractor tool, remove the coil wire pin (tan wire).
  6. Remove the 3 transfer case shift motor bolts and transfer case shift motor.
  7. Remove the 3 coil nuts and washers.
    8. Fig 3: Locating Transfer Case Shift Motor Nuts
    GF0022943Courtesy of FORD MOTOR CO.
    NOTE: It is normal to find metal shavings after removing the self-tapping transfer case bolts.
  8. Remove the 20 transfer case cover bolts.
    9. Fig 4: Locating Transfer Case Bolts
    GF0022944Courtesy of FORD MOTOR CO.
  9. Using the pry bosses, separate the transfer case halves.
    10. Fig 5: Separating Transfer Case Halves
    GF0022945Courtesy of FORD MOTOR CO.
  10. Using the special tool, remove the rear output shaft support bearing.
    • Inspect the bearing for wear or damage. Install a new bearing as necessary.
    11. Fig 6: Locating Rear Output Shaft Support Bearing
    GF0022946Courtesy of FORD MOTOR CO.
  11. Using the special tool, remove the front output shaft rear bearing.
    • Inspect the bearing for wear or damage. Install a new bearing as necessary.
    12. Fig 7: Locating Front Output Shaft Rear Bearing
    GF0022947Courtesy of FORD MOTOR CO.
  12. Remove the snap ring.
    • Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
  13. Remove the caged thrust bearing assembly.
    • Inspect the bearing for wear or damage. Install a new bearing as necessary.
  14. Remove the cam/coil housing.
    15. Fig 8: Locating Cam/Coil Housing
    GF0004166Courtesy of FORD MOTOR CO.
  15. Remove the steel balls and the cam.
    16. Fig 9: Locating Cam & Steel Balls
    GF0022948Courtesy of FORD MOTOR CO.
  16. Remove the wave spring.
  17. Remove and discard the snap ring.
    18. Fig 10: Locating Snap Ring
    GF0022949Courtesy of FORD MOTOR CO.
    CAUTION: When removing the clutch pack assembly, do not separate the clutch pack assembly. Keep tension on the clutch pack during 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 will occur.
  18. Remove the clutch pack assembly.
    19. Fig 11: Locating Clutch Pack Assembly
    GF0022950Courtesy of FORD MOTOR CO.
  19. 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.
    20. Fig 12: Locating Drive Chain & Sprockets Assembly
    GF0022951Courtesy of FORD MOTOR CO.
  20. 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.
    4. Inspect the washers and bearing for wear or damage. Install new components as necessary.
    21. Fig 13: Identifying Thrust Bearing Assembly
    GF0022952Courtesy of FORD MOTOR CO.
  21. Remove and clean the oil pan magnet.
    22. Fig 14: Identifying Magnet
    GF0004082Courtesy of FORD MOTOR CO.
  22. Remove the output shaft sprocket.
    23. Fig 15: Locating Output Shaft Sprocket
    GF0022953Courtesy of FORD MOTOR CO.
  23. Remove the oil pump assembly.
    24. Fig 16: Locating Oil Pump Assembly
    GF0022954Courtesy of FORD MOTOR CO.
  24. Remove the output shaft.
    25. Fig 17: Locating Output Shaft
    GF0022955Courtesy of FORD MOTOR CO.
  25. 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. Do not disassemble the shift cam assembly.
    26. Fig 18: Reduction Shift Fork, Reduction Hub, & Shift Cam (As An Assembly)
    GF0022956Courtesy of FORD MOTOR CO.
  26. Remove the shift fork shaft.
    27. Fig 19: Locating Shift Fork Shaft
    GF0022957Courtesy of FORD MOTOR CO.
  27. Remove the front planet.
    • Using a drift and a hammer, remove the front planet needle bearing, if necessary.
    28. Fig 20: Locating Front Planet Needle Bearing
    GF0022958Courtesy of FORD MOTOR CO.
  28. Remove the ring gear.
    1. Remove the snap ring.
      • Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
    2. Remove the ring gear.
    29. Fig 21: Identifying Ring Gear
    GF0022959Courtesy of FORD MOTOR CO.
    NOTE: Do not let the front output shaft fall when removing the snap ring.
  29. Remove the snap ring and the front output shaft.
    • Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
    30. CAUTION: Carefully remove the seal, do not damage the seal bore.
  30. Remove and discard the front output shaft oil seal.
    31. Fig 22: Locating Front Output Shaft Oil Seal
    GF0022960Courtesy of FORD MOTOR CO.
    CAUTION: Carefully remove the seal, do not damage the seal bore.
  31. Remove and discard the front input shaft seal.
    32. Fig 23: Locating Front Input Shaft Oil Seal
    GF0022961Courtesy of FORD MOTOR CO.
  32. Using a suitable driver, remove the front planet support bearing.
    33. Fig 24: Locating Front Planet Support Bearing
    GF0022962Courtesy of FORD MOTOR CO.
  33. Using a suitable driver, remove the front output shaft support bearing.
    • Inspect the bearing for wear or damage. Install a new bearing as necessary.
    34. Fig 25: Locating Front Output Shaft Support Bearing
    GF0022963Courtesy of FORD MOTOR CO.
  34. Using a suitable tool, remove and discard the shift shaft seal.
    35. Fig 26: Locating Shifter Shaft Seal
    GF0022964Courtesy of FORD MOTOR CO.
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