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Home >> Ford >> 2019 >> Fiesta ST Line, Automatic DCT Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 227 (Transfer Case) >> Disassembly And Assembly >> Transfer Case - Vehicles With: Electronic Shift Transfer Case >> Disassembly
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Transfer Case - Vehicles With: Electronic Shift Transfer Case: Disassembly

WARNING: This page is about a different car, the 2019 Ford F-550 Super Duty, 2019 Ford F-450 Super Duty, 2019 Ford F-350 Super Duty, and 2019 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.

All vehicles 

  1. Using a transmission adjustable mounting arm, secure the transfer case to the bench. Use the General Equipment: Adjustable Mounting Arm
    GFD409477Courtesy of FORD MOTOR COMPANY
  2. Remove the transfer case rear seal. Refer to: Transfer Case Rear Seal - Vehicles With: Flanged Yoke .
  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.

    GFD409430Courtesy 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.
    GFD409478Courtesy of FORD MOTOR COMPANY
  5. Remove the coil nuts.
    GFD409479Courtesy 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.

    GFD409480Courtesy of FORD MOTOR COMPANY
  7. NOTE: Use care not damage the field coil wire.

    Using the pry bosses, separate the transfer case covers.

    GFD409481Courtesy of FORD MOTOR COMPANY
  8. Remove the transfer case field coil.
    GFD409482Courtesy of FORD MOTOR COMPANY
  9. Remove the field coil housing snap ring.
    GFD409483Courtesy of FORD MOTOR COMPANY
  10. Remove the field coil housing.
    GFD409484Courtesy of FORD MOTOR COMPANY
  11. Remove the lock up hub, shift fork and shift fork spring.
    GFD409485Courtesy 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.

    GFD409486Courtesy of FORD MOTOR COMPANY
  13. NOTE: Remove the drive chain and sprockets as an assembly.

    Remove the drive chain and sprockets.

    GFD409487Courtesy of FORD MOTOR COMPANY

    Vehicles equipped with a 6R100 transmission built on or after 31-03-2017 

  14. NOTE: If disassembling the transfer case to replace the front output shaft seal, skip ahead to step 24: Remove the output shaft circlip and the out put shaft.

    Remove the center support assembly.

    GFD409488Courtesy of FORD MOTOR COMPANY

    All vehicles except vehicles equipped with a 6R100 transmission built on or after 31-03-2017 

  15. NOTE: If disassembling the transfer case to replace the front output shaft seal, skip ahead to step 24: Remove the output shaft circlip and the out put shaft.

    Remove the center bearing support assembly.

    GFD409489Courtesy of FORD MOTOR COMPANY

    All vehicles 

  16. NOTE: The pump assembly is not repairable.

    Remove the oil pump assembly and magnet.

    GFD409490Courtesy of FORD MOTOR COMPANY
  17. Remove the shift rail.
    GFD409491Courtesy of FORD MOTOR COMPANY
  18. Remove the shift fork.
    GFD409492Courtesy of FORD MOTOR COMPANY
  19. Remove the output shaft.
    GFD409493Courtesy of FORD MOTOR COMPANY
  20. Remove the reduction hub.
    GFD409494Courtesy 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.

    GFD409495Courtesy of FORD MOTOR COMPANY
  22. NOTE: Replace the inner planet carrier needle bearing if necessary.

    Remove the planet carrier thrust bearing and the front planet carrier.

    GFD409496Courtesy of FORD MOTOR COMPANY
  23. Remove the ring gear circlip and the ring gear.
    GFD409497Courtesy of FORD MOTOR COMPANY
  24. 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.

    GFD409498Courtesy of FORD MOTOR COMPANY
  25. Remove and discard the front input shaft seal and the front output shaft seal.
    GFD409499Courtesy of FORD MOTOR COMPANY
  26. NOTE: If disassembling the transfer case to replace the front output shaft seal, skip ahead to assembly step 8 : Install the front output shaft seal.

    Remove and discard the shift shaft seal.

    GFD409500Courtesy of FORD MOTOR COMPANY
  27. 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
    GFD409501Courtesy of FORD MOTOR COMPANY
  28. 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
    GFD409502Courtesy of FORD MOTOR COMPANY
  29. 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
    GFD409503Courtesy of FORD MOTOR COMPANY
  30. 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
    GFD409504Courtesy of FORD MOTOR COMPANY

    All vehicles except vehicles equipped with a 6R100 transmission built on or after 31-03-2017 

  31. Remove the center support bearing. Use the General Equipment: Copper Hammer Use the General Equipment: Punch
    GFD409505Courtesy of FORD MOTOR COMPANY

    All vehicles 

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

    Clean the transfer case with solvent and dry with compressed air.

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