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Home › Ford › 2000 › Contour SVT › Repair and Diagnosis › External Pages › Different car › Section 1181 (Transfer Case - Electronic Shift) › Disassembly And Assembly › Transfer Case › Disassembly

Transfer Case: Disassembly

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: 2-speed torque-on-demand (TOD) shown, 1-speed TOD similar.

    All vehicles 

    CAUTION: Discard all seals after removing them.
  1. Remove the transfer case. For additional information, refer to TRANSFER CASE .
    2. WARNING: Make sure the holding fixture lock pin is secure.
    Fig 1: Securing Transfer Case To Bench
    G03949506Courtesy of FORD MOTOR CO.
  2. Using the special tool, secure the transfer case to the bench.
  3. Remove the 3 heat shield bolts, then remove the heat shield if equipped.
    Fig 2: Removing Heat Shield
    G03949507Courtesy of FORD MOTOR CO.
  4. If not previously done, remove the drain plug and drain the fluid.
    • When finished draining, install the drain plug and tighten to 15 Nm (11 lb-ft).
    Fig 3: Installing Drain Plug
    G03949508Courtesy of FORD MOTOR CO.
  5. Index mark the rear output flange and the rear output shaft.
    Fig 4: Identifying Index Mark Rear Output Flange And Rear Output Shaft
    G03949499Courtesy of FORD MOTOR CO.
  6. Using the special tool to hold the output flange, remove the nut.
    Fig 5: Removing Nut Using Special Tool
    G03949500Courtesy of FORD MOTOR CO.
  7. Remove the output shaft yoke washer.
  8. Remove the output flange.
  9. Remove and discard the output flange oil seal.
  10. Using the special tools, remove and discard the yoke-to-flange seal.
    Fig 6: Removing Yoke-To-Flange Seal
    G03949501Courtesy of FORD MOTOR CO.

    11. 2-Speed TOD vehicles 

  11. Remove the coil wire pin from the electrical connector.
    1. Remove the connector interlock.
    2. Remove the coil wire pin.
      • Use the electrical connector pin extractor tool.
    Fig 7: Removing Coil Wire Pin From Electrical Connector
    G03949512Courtesy of FORD MOTOR CO.
  12. Remove the 4 transfer case shift motor bolts.
  13. Remove the transfer case shift motor.
    Fig 8: Removing Transfer Case Shift Motor
    G03949513Courtesy of FORD MOTOR CO.

    14. All vehicles 

  14. Remove the 17 transfer case bolts.
    Fig 9: Removing Transfer Case Bolts
    G03949514Courtesy of FORD MOTOR CO.
  15. Remove the 3 clutch coil assembly nuts.
    Fig 10: Removing Clutch Coil Assembly Nuts
    G03949515Courtesy of FORD MOTOR CO.
  16. Separate the transfer case halves at the transfer case pry bosses.
    Fig 11: Separating Transfer Case Halves
    G03949516Courtesy of FORD MOTOR CO.
  17. Remove the snap ring, then using the special tools, remove the rear output shaft support bearing.
    Fig 12: Removing Rear Output Shaft Support Bearing
    G03949517Courtesy of FORD MOTOR CO.
  18. Using the special tools, remove the front output shaft rear bearing.
    Fig 13: Removing Front Output Shaft Rear Bearing
    G03949518Courtesy of FORD MOTOR CO.
  19. Remove the thrust bearing.
    Fig 14: Removing Thrust Bearing
    G03949519Courtesy of FORD MOTOR CO.
  20. Remove the cam and coil housing assembly.
    Fig 15: Removing Cam And Coil Housing Assembly
    G03949520Courtesy of FORD MOTOR CO.
  21. Remove the apply cam and 3 steel balls.
  22. Remove the wave spring.
    Fig 16: Removing Wave Spring
    G03949521Courtesy of FORD MOTOR CO.
  23. Remove the snap ring.
    Fig 17: Removing Snap Ring
    G03949522Courtesy of FORD MOTOR CO.
    24. CAUTION: When removing or installing the clutch pack assembly, do not separate the clutch pack assembly. Keep tension on the clutch pack upon removal. Set the clutch pack assembly on the bench in the same position as it was 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 can occur.
    Fig 18: Removing Clutch Pack Assembly
    G03949523Courtesy of FORD MOTOR CO.
  24. Remove the clutch pack assembly.
  25. Remove the drive chain and the 2 sprockets as an assembly.
    Fig 19: Removing Drive Chain And Sprockets
    G03949524Courtesy of FORD MOTOR CO.
  26. Remove and clean the oil pan magnet.
    Fig 20: Removing Oil Pan Magnet
    G03949525Courtesy of FORD MOTOR CO.
  27. Remove the thrust washer.
    Fig 21: Removing Thrust Washer
    G03949526Courtesy of FORD MOTOR CO.
    28. CAUTION: Do not disassemble the pump assembly.
    Fig 22: Removing Pump Assembly And Rear Output Shaft
    G03949527Courtesy of FORD MOTOR CO.
  28. Remove the pump assembly and the rear output shaft as an assembly.

    29. 2-Speed TOD vehicles 

    CAUTION: Do not disassemble the electric shift cam assembly.
    Fig 23: Removing Electric Shift Cam Assembly
    G03949528Courtesy of FORD MOTOR CO.
  29. Remove the electric shift cam assembly.
  30. Remove the reduction shift fork and the high-low collar as an assembly.
    Fig 24: Removing Reduction Shift Fork And High-Low Collar
    G03949529Courtesy of FORD MOTOR CO.
  31. Remove the shift rail.
    Fig 25: Removing Shift Rail
    G03949530Courtesy of FORD MOTOR CO.

    32. All vehicles 

  32. Using the special tool, remove the oil seal.
    Fig 26: Removing Oil Seal
    G03949531Courtesy of FORD MOTOR CO.
  33. Remove the front planetary gear set assembly.
    1. Expand the snap ring.
    2. Remove the front planetary gear set assembly.
      Fig 27: Removing Front Planetary Gear Set Assembly
      G03949532Courtesy of FORD MOTOR CO.
  34. Using a drift and hammer, remove the output shaft bushing and bearing, if necessary.
    Fig 28: Removing Output Shaft Bushing And Bearing
    G03949533Courtesy of FORD MOTOR CO.
  35. If planetary gear carrier support bearing removal is necessary, remove the snap ring.
    Fig 29: Removing Snap Ring
    G03949534Courtesy of FORD MOTOR CO.
  36. Using a suitable press and the special tool, remove the planetary gear carrier support bearing.
    Fig 30: Removing Planetary Gear Carrier Support Bearing
    G03949535Courtesy of FORD MOTOR CO.
  37. Remove the ring gear snap ring.
  38. Remove the planetary ring gear.
  39. While holding the front output shaft and flange, remove the snap ring.
    Fig 31: Removing Ring Gear Snap Ring
    G03949536Courtesy of FORD MOTOR CO.
  40. Remove the front output shaft and flange.
    Fig 32: Removing Front Output Shaft And Flange
    G03949537Courtesy of FORD MOTOR CO.
  41. Using the special tools, remove the oil seal.
    Fig 33: Removing Oil Seal
    G03949538Courtesy of FORD MOTOR CO.
  42. Using the special tools, remove the front output shaft support bearing.
    Fig 34: Removing Front Output Shaft Support Bearing
    G03949539Courtesy of FORD MOTOR CO.

    43. 2-Speed TOD vehicles 

  43. Remove the shifter shaft seal.
    Fig 35: Removing Shifter Shaft Seal
    G03949540Courtesy of FORD MOTOR CO.
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