Transfer Case: Disassembly

TRANSFER CASE DISASSEMBLED VIEW 

Fig 1: Exploded View Of Transfer Case (Items 1-6)

Courtesy of FORD MOTOR CO.

Fig 2: Transfer Case Reference Table (Items 7-45)

Courtesy of FORD MOTOR CO.

Fig 3: Transfer Case Reference Table (Items 46-86)

Courtesy of FORD MOTOR CO.

1. Remove the transfer case from the vehicle. For additional information, refer to TRANSFER CASE .
2. Attach the transfer case to the special tool.
   Fig 4: Attaching Transfer Case To Special Tool

   Courtesy of FORD MOTOR CO.
CAUTION: Index-mark the rear output shaft and the flange.
CAUTION: The nut has a self-locking feature. Discard the nut and the washer after removing them.
Fig 5: Holding Flange & Removing Nut
Courtesy of FORD MOTOR CO.
3. Use the special tool to prevent the flange from turning. Remove and discard the nut and the washer.
4. Using a suitable puller, remove the flange.
   Fig 6: Removing Flange

   Courtesy of FORD MOTOR CO.
5. Remove the oil seal if it remains on the rear output shaft.
   Fig 7: Identifying Oil Seal From Rear Output Shaft

   Courtesy of FORD MOTOR CO.
6. Using the special tool, remove the oil seal.
   Fig 8: Removing Oil Seal

   Courtesy of FORD MOTOR CO.
7. Remove the spacer.
   Fig 9: Removing Spacer

   Courtesy of FORD MOTOR CO.
8. Remove the bolts retaining the harness to the motor assembly and connector.
   Fig 10: Removing Bolts Retaining Harness To Motor Assembly

   Courtesy of FORD MOTOR CO.
9. Remove the rear bolt.
   Fig 11: Removing Rear Bolt

   Courtesy of FORD MOTOR CO.
10. Remove the front bolt and the motor assembly and connector.
    Fig 12: Removing Front Bolt And Motor Assembly

    Courtesy of FORD MOTOR CO.
11. Remove the bolts that retain the transfer case cover to the transfer case.
    Fig 13: Removing Transfer Case Cover Bolts

    Courtesy of FORD MOTOR CO.
12. Remove the bolts that retain the transfer case to the transfer case cover.
    Fig 14: Removing Transfer Case Cover Bolts

    Courtesy of FORD MOTOR CO.
NOTE: Position the assembly so that the front of the transfer case is facing downward.
Fig 15: Separate Transfer Case Cover From Transfer Case
Courtesy of FORD MOTOR CO.
13. Insert a breaker bar between the pry bosses, and separate the transfer case cover from the transfer case.
14. Remove the snap ring that retains the bearing in the case.
    Fig 16: Removing Snap Ring

    Courtesy of FORD MOTOR CO.
15. Using the special tools, remove the bearing.
    Fig 17: Removing Bearing

    Courtesy of FORD MOTOR CO.
16. Using the special tools, remove the needle bearing.
    Fig 18: Removing Needle Bearing

    Courtesy of FORD MOTOR CO.
17. Remove the following:
    1. Remove the shift collar hub.
    2. Remove the return spring.
    3. Remove the lockup collar and the lockup fork as an assembly.
    4. Remove the electric shift cam assembly.
    5. Remove the shift rail.
       Fig 19: Removing Transfer Case Components

       Courtesy of FORD MOTOR CO.
18. Remove the snap ring.
    Fig 20: Removing Snap Ring

    Courtesy of FORD MOTOR CO.
19. Remove the lockup hub and the sleeve return spring from the lockup collar.
    Fig 21: Removing Lockup Hub And Sleeve Return Spring

    Courtesy of FORD MOTOR CO.
20. Remove the snap ring and the spacer.
    Fig 22: Removing Snap Ring And Spacer

    Courtesy of FORD MOTOR CO.
21. Remove the drive chain, the driven sprocket, and the drive sprocket as an assembly.
    Fig 23: Removing Drive Chain, Driven Sprocket, And Drive Sprocket

    Courtesy of FORD MOTOR CO.
22. Remove the magnet and the oil strainer from the slot in the transfer case.
    Fig 24: Removing Magnet And Oil Strainer

    Courtesy of FORD MOTOR CO.
23. Remove the rear output shaft and the pump assembly as an assembly.
    Fig 25: Removing Rear Output Shaft And Pump Assembly

    Courtesy of FORD MOTOR CO.
24. Rotate the pump assembly to align the keyway in the cover and the spring pin in the rear output shaft, and separate the pump from the shaft.
    Fig 26: Aligning Keyway In Cover And Spring Pin In Rear Output Shaft

    Courtesy of FORD MOTOR CO.
CAUTION: The height of the oil pump spring pin must be measured before removal so that during assembly, it can be installed at the correct height to make sure that the oil pump shaft rotates with the rear output shaft.
Fig 27: Measuring Pump Drive Pin Height
Courtesy of FORD MOTOR CO.
25. Using a micrometer, measure and record the pump drive pin height above the diameter of the rear output shaft, and remove the drive pin from the rear output shaft.
CAUTION: Do not let the front output shaft assembly fall out of the case while removing the snap ring.
Fig 28: Removing Snap Ring
Courtesy of FORD MOTOR CO.
26. Remove the snap ring. Discard the snap ring if deformed during removal.
27. Remove the front output shaft assembly.
    Fig 29: Removing Front Output Shaft Assembly

    Courtesy of FORD MOTOR CO.
28. Remove the reduction fork assembly and the reduction hub as an assembly.
    Fig 30: Removing Reduction Fork Assembly

    Courtesy of FORD MOTOR CO.
29. Remove the six bolts retaining the front adapter assembly to the case.
    Fig 31: Removing Bolts Retaining Front Adapter Assembly To Case

    Courtesy of FORD MOTOR CO.
30. Remove the front adapter assembly, the input shaft assembly, and the complete carrier assembly as an assembly.
    Fig 32: Removing Front Adapter Assembly, Input Shaft Assembly, And Complete Carrier Assembly

    Courtesy of FORD MOTOR CO.
31. Using snap ring pliers, expand the tangs of the large snap ring and remove the complete carrier assembly and the input shaft assembly from the front adapter.
    Fig 33: Removing Complete Carrier Assembly And Input Shaft Assembly

    Courtesy of FORD MOTOR CO.
32. Remove the large snap ring from the front adapter.
    Fig 34: Removing Large Snap Ring From Front Adapter

    Courtesy of FORD MOTOR CO.
33. Using a suitable tool, remove the oil seal from the front adapter.
    Fig 35: Removing Oil Seal From Front Adapter

    Courtesy of FORD MOTOR CO.
34. Remove the snap ring.
    Fig 36: Removing Snap Ring

    Courtesy of FORD MOTOR CO.
35. Using the special tool and a suitable press, remove the bearing.
    Fig 37: Removing Bearing

    Courtesy of FORD MOTOR CO.
36. Remove the thrust washer and the input shaft assembly.
    Fig 38: Removing Thrust Washer And Input Shaft Assembly

    Courtesy of FORD MOTOR CO.
37. Remove the snap ring, the thrust plate, and the sun gear.
    Fig 39: Removing Snap Ring, Thrust Plate, And Sun Gear

    Courtesy of FORD MOTOR CO.
NOTE: Remove and discard both the sleeve bearing and the needle bearing if either one is worn/damaged.
Fig 40: Removing Needle Bearing And Sleeve Bearing From Input Shaft
Courtesy of FORD MOTOR CO.
38. Using the special tools and a suitable press, remove the needle bearing and the sleeve bearing from the input shaft.
39. Using a suitable tool, remove the oil seal.
    Fig 41: Removing Oil Seal

    Courtesy of FORD MOTOR CO.
40. Remove the snap ring retaining the bearing to the case.
    Fig 42: Removing Snap Ring Retaining Bearing To Case

    Courtesy of FORD MOTOR CO.
41. Using the special tools, remove the bearing.
    Fig 43: Removing Bearing

    Courtesy of FORD MOTOR CO.
42. Using a suitable tool, remove the oil seal.
    Fig 44: Removing Oil Seal

    Courtesy of FORD MOTOR CO.
43. Remove the shift fork facings.
    Fig 45: Removing Shift Fork Facings

    Courtesy of FORD MOTOR CO.
44. Remove the electric shift cam from the shift shaft.
    Fig 46: Removing Electric Shift Cam From Shift Shaft

    Courtesy of FORD MOTOR CO.
WARNING: Keep fingers away from spring ends. Failure to follow these instructions can result in personal injury.
Fig 47: Removing Torsion Spring And Spacer From Shift Shaft
Courtesy of FORD MOTOR CO.
45. Remove the torsion spring and the spacer from the shift shaft.