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Home >> Ford >> 2018 >> Focus S, Standard Trans >> Repair and Diagnosis (Single Page) >> External Pages >> Different car >> Section 249 (Transfer Case) >> Disassembly And Assembly >> Transfer Case - Vehicles With: 2-Speed Torque On Demand Transfer Case >> Disassembly
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Transfer Case - Vehicles With: 2-Speed Torque On Demand Transfer Case: Disassembly

WARNING: This page is about a different car, the 2018 Lincoln Navigator. 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

    GFD274083Courtesy 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.

    GFD274059Courtesy of FORD MOTOR COMPANY
    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.
    GFD274116Courtesy of FORD MOTOR COMPANY
  5. Remove the coil nuts and washers.
    GFD274085Courtesy 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.

    GFD274086Courtesy of FORD MOTOR COMPANY
  7. Using the pry bosses, separate the transfer case covers.
    GFD274087Courtesy of FORD MOTOR COMPANY
  8. Remove the transfer case field coil.
    GFD274088Courtesy of FORD MOTOR COMPANY
  9. Remove the coil housing snap ring and spacer.
    GFD274089Courtesy of FORD MOTOR COMPANY
  10. Remove the caged thrust bearing assembly.

    • Install a new bearing as necessary.

    GFD274117Courtesy of FORD MOTOR COMPANY
  11. Remove the coil housing.
    GFD274118Courtesy of FORD MOTOR COMPANY
  12. Remove the steel balls and the cam.
    GFD274119Courtesy of FORD MOTOR COMPANY
  13. Remove the wave spring.
    GFD274093Courtesy of FORD MOTOR COMPANY
  14. Remove clutch pack circlip.
    GFD274094Courtesy of FORD MOTOR COMPANY
  15. NOTE: 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.
    NOTE: If the clutch pack is disassembled, a new clutch pack and armature must be installed. Failure to install a new clutch pack can result in component failure.

    Remove the clutch pack assembly with the armature.

    GFD274120Courtesy of FORD MOTOR COMPANY
  16. Remove the clutch pack spacer.
    GFD274121Courtesy of FORD MOTOR COMPANY
  17. Remove the drive chain and the sprockets as an assembly.

    • Install new components as necessary.

    GFD274122Courtesy of FORD MOTOR COMPANY
  18. Remove the output shaft sprocket spacer.
    GFD274123Courtesy of FORD MOTOR COMPANY
  19. Remove the thrust bearing assembly.

    • NOTE: The upper thrust washer may be attached to the sprocket.

      Remove the thrust washer.

    • Remove the thrust bearing.

    • Remove the thrust washer.

    • Install new components as necessary.

    GFD274124Courtesy of FORD MOTOR COMPANY
  20. Remove the magnet from its slot in the case.
    GFD274100Courtesy of FORD MOTOR COMPANY
  21. NOTE: The pump assembly is not repairable.

    Remove the oil pump assembly.

    GFD274125Courtesy of FORD MOTOR COMPANY
  22. Remove the shift rail.
    GFD274126Courtesy of FORD MOTOR COMPANY
  23. Remove the shift fork.
    GFD274127Courtesy of FORD MOTOR COMPANY
  24. Remove the output shaft.
    GFD274128Courtesy of FORD MOTOR COMPANY
  25. Remove the reduction hub.
    GFD274129Courtesy of FORD MOTOR COMPANY
  26. NOTE: The electric shift cam is serviced as an assembly. Do not disassemble the shift cam assembly.

    Remove the electric shift cam assembly.

    GFD274130Courtesy of FORD MOTOR COMPANY
  27. Remove the planetary carrier thrust bearing.
    GFD274131Courtesy of FORD MOTOR COMPANY
  28. Remove the ring gear circlip.
    GFD274132Courtesy of FORD MOTOR COMPANY
  29. NOTE: Replace the inner planetary carrier needle bearing if necessary.

    Remove the front planetary carrier.

    GFD274133Courtesy of FORD MOTOR COMPANY
  30. Remove the ring gear.
    GFD274134Courtesy of FORD MOTOR COMPANY
  31. 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 output shaft.

    GFD274135Courtesy of FORD MOTOR COMPANY
  32. Remove and discard the front input shaft seal and the front output shaft seal.
    GFD274136Courtesy of FORD MOTOR COMPANY
  33. 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
    GFD274137Courtesy of FORD MOTOR COMPANY
  34. 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
    GFD274138Courtesy of FORD MOTOR COMPANY
  35. 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
    GFD274139Courtesy of FORD MOTOR COMPANY
  36. Using the special tool and a Slide Hammer, remove the front planetary carrier bearing. Use Special Service Tool: 308-047 (T77F-1102-A) Remover, Bearing Cup. Use the General Equipment: Slide Hammer
    GFD274140Courtesy of FORD MOTOR COMPANY
  37. Clean and inspect the components of the transfer case for damage and install new components as necessary.
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