Transfer Case - Expedition: Disassembly

WARNING: This page is about a different variant/trim than selected.

NOTE: Use a suitable cleaning solvent to clean the transfer case. 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.

Fig 1: Rotating Transfer Case Output Shaft
Courtesy of FORD MOTOR CO.
Drain the fluid from the transfer case, if not done previously.

Fig 2: Locating Drain Fluid From Transfer Case
Courtesy of FORD MOTOR CO.
Using a suitable seal puller, remove and discard the rear output shaft seal.

Fig 3: 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 4: Locating Coil Wire Pin From 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 5: 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.

Fig 6: Locating Transfer Case Cover Bolts

Courtesy of FORD MOTOR CO.

Remove the 20 transfer case cover bolts.
Using the pry bosses, separate the transfer case halves.

Fig 7: 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 8: Removing 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 9: Removing 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 10: Locating Cam/Coil Housing
Courtesy of FORD MOTOR CO.
Remove the steel balls and the cam.

Fig 11: Locating Steel Balls And Cam
Courtesy of FORD MOTOR CO.
Remove the wave spring.
Remove and discard the snap ring.

Fig 12: Locating Snap Ring
Courtesy of FORD MOTOR CO.

NOTE: 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.

Fig 13: Locating Clutch Pack Assembly

Courtesy of FORD MOTOR CO.

Remove the clutch pack assembly.
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 14: 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 15: Identifying Thrust Bearing And Thrust Washer
    Courtesy of FORD MOTOR CO.
Remove and clean the oil pan magnet.

Fig 16: Identifying Oil Pan Magnet
Courtesy of FORD MOTOR CO.
Remove the output shaft sprocket.

Fig 17: Locating Output Shaft Sprocket
Courtesy of FORD MOTOR CO.
Remove the oil pump assembly.

Fig 18: Locating Oil Pump Assembly
Courtesy of FORD MOTOR CO.
Remove the output shaft.

Fig 19: 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 20: Locating Reduction Shift Fork, Reduction Hub And Shift Cam Assembly
  Courtesy of FORD MOTOR CO.
Remove the shift fork shaft.

Fig 21: Locating Shift Fork Shaft
Courtesy of FORD MOTOR CO.
Remove the front planet.
- Using a drift and a hammer, remove the front planet needle bearing, if necessary.
  
  Fig 22: Locating Front Planet Needle Bearing
  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 23: Identifying Ring Gear
  Courtesy of FORD MOTOR CO.

NOTE: 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.

NOTE: Carefully remove the seal, do not damage the seal bore.

Fig 24: Locating Front Output Shaft Oil Seal

Courtesy of FORD MOTOR CO.

Remove and discard the front output shaft oil seal.

NOTE: Carefully remove the seal, do not damage the seal bore.

Fig 25: Locating Front Input Shaft Seal

Courtesy of FORD MOTOR CO.

Remove and discard the front input shaft seal.
Using a suitable driver, remove the front planet support bearing.

Fig 26: Removing Front Planet Support Bearing
Courtesy of FORD MOTOR CO.
Using a suitable driver, remove the front output shaft support bearing.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
  
  Fig 27: Removing Front Output Shaft Support Bearing
  Courtesy of FORD MOTOR CO.
Using a suitable tool, remove and discard the shift shaft seal.

Fig 28: Removing Shift Shaft Seal
Courtesy of FORD MOTOR CO.