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Transfer Case - 2-Speed Torque-On-Demand: Disassembly

NOTICE: 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 exterior with solvent and dry with compressed air.
Using the Transmission Holding Fixture, secure the transfer case to a work bench. Rotate the transfer case so that the output shaft is pointing upward.
Remove and discard the rear output shaft seal.

Fig 1: Locating Rear Output Shaft Seal
Courtesy of FORD MOTOR CO.
Remove the coil wire pin from the electrical connector.
- Remove the wire connector inner retainer.
- Press the release tab and remove the coil wire pin (tan wire).
Fig 2: Locating Coil Wire Pin In Electrical Connector
Courtesy of FORD MOTOR CO.
Loosen the 2 transfer case shift motor bracket nuts and remove the bracket bolt.
Remove the 3 transfer case shift motor bolts and transfer case shift motor.
Remove the 3 coil nuts and washers.

Fig 3: Locating Coil Nuts And Washers
Courtesy of FORD MOTOR CO.
NOTE: It is normal to find metal shavings after removing the self-tapping transfer case bolts.
Remove the 20 transfer case cover bolts.

Fig 4: Locating Transfer Case Bolt
Courtesy of FORD MOTOR CO.
Using the pry bosses, separate the transfer case halves.

Fig 5: Separating Transfer Case Halves
Courtesy of FORD MOTOR CO.
Using the Bearing Cup Remover and the Slide Hammer, remove the rear output shaft support bearing.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
Fig 6: Locating Rear Output Shaft Support Bearing
Courtesy of FORD MOTOR CO.
Using the Bearing Cup Remover and the Slide Hammer, remove the front output shaft rear bearing.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
Fig 7: Locating Front Output Shaft Rear Bearing
Courtesy of FORD MOTOR CO.
Remove the snap ring.
- Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
Remove the caged thrust bearing assembly.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
Remove the cam/coil housing.

Fig 8: Locating Cam/Coil Housing
Courtesy of FORD MOTOR CO.
Remove the steel balls and the cam.

Fig 9: Locating Steel Balls And Cam
Courtesy of FORD MOTOR CO.
Remove the wave spring.
Remove and discard the snap ring.

Fig 10: Locating Snap Ring
Courtesy of FORD MOTOR CO.
NOTICE: 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.
NOTICE: If the clutch pack is disassembled, a new clutch pack must be installed and the armature transferred. Failure to install a new clutch pack can result in component failure.

Remove the clutch pack assembly with the armature.

Fig 11: Locating Clutch Pack Assembly
Courtesy of FORD MOTOR CO.
Remove the drive chain and the sprockets as an assembly.
- Inspect the drive chain for wear or damage. Inspect the sprockets for broken or cracked teeth. Install new components as necessary.
Fig 12: Locating Drive Chain And Sprockets Assembly
Courtesy of FORD MOTOR CO.
Remove the thrust bearing assembly.
1. Remove the thrust washer.
  - The upper thrust washer may be attached to the sprocket.
2. Remove the thrust bearing.
3. Remove the thrust washer.
  - Inspect the washers and bearing for wear or damage. Install new components as necessary.
Fig 13: Identifying Thrust Bearing And Thrust Washer
Courtesy of FORD MOTOR CO.
Remove and clean the oil pan magnet.

Fig 14: Identifying Oil Pan Magnet
Courtesy of FORD MOTOR CO.
Remove the output shaft sprocket.

Fig 15: Locating Output Shaft Sprocket
Courtesy of FORD MOTOR CO.
Remove the oil pump assembly.

Fig 16: Locating Oil Pump Assembly
Courtesy of FORD MOTOR CO.
Remove the output shaft.

Fig 17: Locating Output Shaft
Courtesy of FORD MOTOR CO.
Remove the reduction shift fork, the reduction hub and the shift cam as an assembly.
- Separate and inspect the reduction hub and the reduction shift fork for wear or damage. Do not disassemble the shift cam assembly.
Fig 18: Locating Reduction Shift Fork, Reduction Hub And Shift Cam Assembly
Courtesy of FORD MOTOR CO.
Remove the shift fork shaft.

Fig 19: Locating Shift Fork Shaft
Courtesy of FORD MOTOR CO.
Remove the front planet.
- Remove the front planet needle bearing, if necessary.
Fig 20: Locating Front Planet
Courtesy of FORD MOTOR CO.
Remove the ring gear.
1. Remove the snap ring.
  - Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
2. Remove the ring gear.
Fig 21: Identifying Ring Gear And Snap Ring
Courtesy of FORD MOTOR CO.
NOTICE: Do not let the front output shaft fall when removing the snap ring.
Remove the snap ring and the front output shaft.
- Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
Fig 22: Removing Snap Ring And Front Output Shaft
Courtesy of FORD MOTOR CO.
NOTICE: Carefully remove the seal, do not damage the seal bore.
Remove and discard the front output shaft oil seal.

Fig 23: Locating Front Output Shaft Oil Seal
Courtesy of FORD MOTOR CO.
NOTICE: Carefully remove the seal, do not damage the seal bore.
Remove and discard the front input shaft seal.

Fig 24: Locating Front Input Shaft Seal
Courtesy of FORD MOTOR CO.
Remove the front planet support bearing.

Fig 25: Locating Front Input Shaft Bearing
Courtesy of FORD MOTOR CO.
Remove the front output shaft support bearing.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
Fig 26: Removing Front Output Shaft Support Bearing
Courtesy of FORD MOTOR CO.
Remove and discard the shift shaft seal.

Fig 27: Locating Shifter Shaft Seal

G06128078

Courtesy of FORD MOTOR CO.