Transfer Case - Vehicles With: Electronic Shift Transfer Case: Disassembly

WARNING: This page is about a different car, the 2015 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.

1.

NOTE: Seal all openings before cleaning the transfer case exterior. This will prevent entry of dirt and water, which may cause damage to internal components.

Using a transmission adjustable mounting arm, secure the transfer case to the bench. Clean the transfer case with solvent and dry with compressed air.

Use the General Equipment: Adjustable Mounting Arm

Courtesy of FORD MOTOR COMPANY

2.

Remove the transfer case rear seal. Refer to: Transfer Case Rear Seal .

3.

Remove the coil wire pin from the electrical connector.
- 1.
  
  Remove the inner retainer from the wire connector.
- 2.
  
  Press the release tab and remove the coil wire pin.

Courtesy of FORD MOTOR COMPANY

4.
- 1.
  
  Loosen the transfer case shift motor bracket nuts.
- 2.
  
  Remove the transfer case shift motor bracket bolt.
- 3.
  
  Remove the transfer case shift motor bolts.
- 4.
  
  Remove the transfer case shift motor.

Courtesy of FORD MOTOR COMPANY

5.

Remove the coil nuts and washers.

Courtesy of FORD MOTOR COMPANY

6.

NOTE: The transfer case bolts are self tapping, and it is normal to find metal shavings while removing the cover.

Remove the transfer case bolts.

Courtesy of FORD MOTOR COMPANY

7.

NOTE: Use care not damage the field coil wire.

Using the pry bosses, separate the transfer case covers.

Courtesy of FORD MOTOR COMPANY

8.

Remove the transfer case field coil.

Courtesy of FORD MOTOR COMPANY

9.

Remove the field coil housing snap ring.

Courtesy of FORD MOTOR COMPANY

10.

Remove the field coil housing.

Courtesy of FORD MOTOR COMPANY

11.

Remove the lock up hub, shift fork and shift fork spring.

Courtesy of FORD MOTOR COMPANY

12.

NOTE: Remove the lockup hub assembly as a single unit. If disassembly is required, proceed with the following.

Disassemble the lockup hub assembly.
- 1.
  
  Remove the lockup hub snap ring.
- 2.
  
  Separate the lockup collar.
- 3.
  
  Separate the 2 lockup springs.
- 4.
  
  Separate the lockup hub.
- 5.
  
  Remove the armature.

Courtesy of FORD MOTOR COMPANY

13.

NOTE: Remove the drive chain and sprockets as an assembly.

Remove the drive chain and sprockets.

Courtesy of FORD MOTOR COMPANY

14.

Remove the sprocket thrust washer.

Courtesy of FORD MOTOR COMPANY

15.

Remove the magnet from its slot in the case.

Courtesy of FORD MOTOR COMPANY

16.

NOTE: The pump assembly is not repairable.

Remove the oil pump assembly.

Courtesy of FORD MOTOR COMPANY

17.

Remove the shift rail.

Courtesy of FORD MOTOR COMPANY

18.

Remove the shift fork.

Courtesy of FORD MOTOR COMPANY

19.

Remove the output shaft.

Courtesy of FORD MOTOR COMPANY

20.

Remove the reduction hub.

Courtesy of FORD MOTOR COMPANY

21.

NOTE: The electric shift cam is serviced as an assembly. Do not disassemble the shift cam assembly.

Remove the electric shift cam assembly.

Courtesy of FORD MOTOR COMPANY

22.

Remove the planet carrier thrust bearing.

Courtesy of FORD MOTOR COMPANY

23.

Remove the ring gear circlip.

Courtesy of FORD MOTOR COMPANY

24.

NOTE: Replace the inner planet carrier needle bearing if necessary.

Remove the front planet carrier.

Courtesy of FORD MOTOR COMPANY

25.

Remove the ring gear.

Courtesy of FORD MOTOR COMPANY

26.

NOTE: Do not let the front output shaft fall while removing the snap ring or damage to the component may occur.

Remove the output shaft circlip and the out put shaft.

Courtesy of FORD MOTOR COMPANY

27.

Remove and discard the front input shaft seal and the front output shaft seal.

Courtesy of FORD MOTOR COMPANY

28.

Using the special tool with the Slide Hammer, remove the rear output shaft bearing.
Use Special Service Tool: 308-047 (T77F-1102-A) Remover, Bearing Cup.

Use the General Equipment: Slide Hammer

Courtesy of FORD MOTOR COMPANY

29.

Using the special tool and a Slide Hammer, remove the front output shaft support bearing.
Use Special Service Tool: 307-318 Remover, Stator Bearing.

Use the General Equipment: Slide Hammer

Courtesy of FORD MOTOR COMPANY

30.

Using the special tool with the Slide Hammer, remove the front output shaft bearing.
Use Special Service Tool: 308-047 (T77F-1102-A) Remover, Bearing Cup.

Use the General Equipment: Slide Hammer

Courtesy of FORD MOTOR COMPANY

31.

Using the special tool and a Slide Hammer, remove the front planet carrier bearing.
Use Special Service Tool: 308-047 (T77F-1102-A) Remover, Bearing Cup.

Use the General Equipment: Slide Hammer

Courtesy of FORD MOTOR COMPANY

32.

Clean and inspect the components of the transfer case for damage and install new components as necessary.