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

WARNING: This page is about a different car, the 2018 Ford F-550 Super Duty, 2018 Ford F-450 Super Duty, 2018 Ford F-350 Super Duty, and 2018 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.

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.

Clean the transfer case with solvent and dry with compressed air.
Using a transmission adjustable mounting arm, secure the transfer case to the bench. Use the General Equipment: Adjustable Mounting Arm

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

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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.

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NOTE: Use care not damage the field coil wire.

Using the pry bosses, separate the transfer case covers.

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Remove the transfer case field coil.

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Remove the field coil housing snap ring.

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Remove the field coil housing.

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

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

Remove the drive chain and sprockets.

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Remove the center bearing support assembly.

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NOTE: The pump assembly is not repairable.

Remove the oil pump assembly and magnet.

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Remove the shift rail.

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Remove the shift fork.

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Remove the output shaft.

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Remove the reduction hub.

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

Remove the electric shift cam assembly.

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

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

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Remove the ring gear circlip and the ring gear.

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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.

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

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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

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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

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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

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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

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Clean and inspect the components of the transfer case for damage and install new components as necessary.
Remove the center support bearing. Use the General Equipment: Copper Hammer Use the General Equipment: Punch

GFD205343

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