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Transfer Case - Vehicles With: Manual 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. 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.

    GFD409518Courtesy of FORD MOTOR COMPANY
  4. Using the pry bosses, separate the transfer case covers.
    GFD409481Courtesy of FORD MOTOR COMPANY
  5. Remove the shift lock hub snap ring.
    GFD409519Courtesy of FORD MOTOR COMPANY
  6. Visually notice alignment, remove the shift fork lock hub.
    GFD409520Courtesy of FORD MOTOR COMPANY
  7. Remove the lock hub shift fork assembly.
    GFD409521Courtesy of FORD MOTOR COMPANY
  8. NOTE: Remove the drive chain and sprockets as an assembly.

    Remove the drive chain and sprockets.

    GFD409522Courtesy of FORD MOTOR COMPANY

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

  9. NOTE: If disassembling the transfer case to replace the front output shaft seal, skip ahead to step 18: 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 

  10. NOTE: If disassembling the transfer case to replace the front output shaft seal, skip ahead to step 18: Remove the output shaft circlip and the out put shaft.

    Remove the center bearing support assembly.

    GFD409514Courtesy of FORD MOTOR COMPANY

    All vehicles 

  11. Remove the shift rail.
    GFD409523Courtesy of FORD MOTOR COMPANY
  12. NOTE: The pump assembly is not repairable.

    Remove the oil pump assembly and magnet.

    GFD409524Courtesy of FORD MOTOR COMPANY
  13. Remove the output shaft.
    GFD409525Courtesy of FORD MOTOR COMPANY
  14. Remove the shift fork assembly.
    GFD409526Courtesy of FORD MOTOR COMPANY
  15. 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
  16. Remove the ring gear circlip and the ring gear.
    GFD409497Courtesy of FORD MOTOR COMPANY
  17. NOTE: The manual shift cam is serviced as an assembly. Do not disassemble the shift cam assembly.

    Remove the manual shift assembly.

    • Loosen the shift lever set screw.

    • remove the shift lever.

    • Remove the shift guide plate and guide plate spring arm.

    GFD409527Courtesy of FORD MOTOR COMPANY
  18. 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
  19. Remove and discard the front input shaft seal and the front output shaft seal.
    GFD409499Courtesy of FORD MOTOR COMPANY
  20. 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.

    GFD409528Courtesy of FORD MOTOR COMPANY
  21. 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
  22. 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
  23. 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
  24. 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 

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

    All vehicles 

  26. Remove the contamination and deposits from the transfer case housing and cover using a plastic scraper. Clean the transfer case housing and cover using a soft bristle brush to remove the contamination. Clean any remaining lip seal coating that may still be present on the housing or cover bores with a wire brush. Make sure the vent fitting and housing pockets are clean and clear. Use the General Equipment: Spatula
    GFD409529Courtesy of FORD MOTOR COMPANY
  27. Clean the transfer case housing and cover flange sealing surfaces. Refer to: RTV Sealing Surface Cleaning and Preparation .
GFD409530Courtesy of FORD MOTOR COMPANY
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