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Transfer Case: Disassembly

WARNING: This page is about a different car, the 2007 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Transfer Case Disassembled View
GF0010647Courtesy of FORD MOTOR CO.
Item Part Number Description
1 7050 Front adapter assembly
2 7B215 Oil seal (also part of 7050)
3 - Spiral pin (part of 7050)
4 - Front adapter (part of 7050)
5 7917 Snap ring (also part of 7050)
6 7917 Snap ring
7 7025 Bearing
8 7A385 Thrust washer
9 7C122 Snap ring
10 7B066 Thrust plate
11 7D063 Sun gear
12 7017 Input shaft assembly
13 - Snap ring
14 7D164 Lockup hub
15 7D126 Sleeve return spring
16 7106 Lockup collar
17 7177 Drive sprocket
18 7065 Sleeve bearing (also part of 7017)
19 7120 Needle bearing (also part of 7017)
20 - Input shaft (part of 7017)
21 - Pinion thrust washer (part of 7A398)
22 - Needle roller bearings (part of 7A398)
23 - Pinion needle spacer (part of 7A398)
24 - Pinion gear (part of 7A398)
25 7A398 Complete carrier assembly
26 - Planet pinion pin (part of 7A398)
27 - Planet carrier (part of 7A398)
28 7A443 Bolt
29 7034 Breather barb
30 7A153 Ring gear (part of 7005)
31 7100 Reduction hub
32 - Shaft assembly
33 7B362 Spring pin (also part of 7005)
34 - Output shaft
35 7A149 Pump assembly
36 - Hose clamp
37 - Hose
38 7A098 Oil strainer
39 7C430 Shift fork facing (also part of 7289)
40 - Reduction shift fork (part of 7289)
41 7289 Lockup fork
42 7219 Return spring
43 7100 Shift collar hub
44 7917 Snap ring (also part of 7005)
45 7025 Bearing (also part of 7005)
46 - Transfer cover assembly (part of 7005)
47 - Identification tag
48 7A443 Bolt
49 7A443 Bolt
50 7K470 Bracket
51 - Bolt
52 - J clip
53 7045 Nut
54 7B368 Washer
55 7052 Oil seal
56 7B214 Flange
57 7G360 Motor assembly and connector
58 7B215 Oil seal
59 7072 Spacer
60 7A010 Pipe plugs
61 7B216 Oil seal (also part of 7005)
62 - Transfer case cover (part of 7005)
63 - Drive chain
64 7917 Snap ring
65 7127 Needle bearing (also part of 7005)
66 7119 Spacer
67 7240 Shift rail
68 - Driven sprocket
69 7F063 Electric shift cam
70 7W074 Torsion spring
71 7Z112 Spacer
72 7N095 Shift shaft
73 - Cam pin (part of 7289)
74 - Cam roller (part of 7289)
75 7289 Reduction fork assembly
76 7E290 Magnet
77 7917 Snap ring
78 7917 Snap ring (also part of 7005)
79 7025 Bearing (also part of 7005)
80 7B362 Dowel pin (also part of 7005)
81 - Transfer Case (part of 7005)
82 7005 Transfer case assembly
83 7B215 Oil seal
84 7C016 Dust deflector (also part of 7061)
85 7061 Front output shaft assembly
86 - Front output shaft (part of 7061)
  1. Remove the transfer case from the vehicle. For additional information, refer to Transfer Case  in this article.
  2. Attach the transfer case to the special tool.
    Fig 2: Identifying Special Mounting Tool For Transfer Case
    GF0010648Courtesy of FORD MOTOR CO.
    3. 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 3: View Of Washer, Nut And Alignment Marks
    GF0010635Courtesy 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 4: Identifying Special Tool For Removing Flange
    GF0010636Courtesy of FORD MOTOR CO.
  5. Remove the oil seal if it remains on the rear output shaft.
    Fig 5: Removing Oil Seal Remains On Rear Output Shaft
    GF0010637Courtesy of FORD MOTOR CO.
  6. Using the special tool, remove the oil seal.
    Fig 6: Identifying Special Tool For Removing Oil Seal
    GF0010638Courtesy of FORD MOTOR CO.
  7. Remove the spacer.
    Fig 7: Locating Spacer On Rear Output Shaft
    GF0010649Courtesy of FORD MOTOR CO.
  8. Remove the bolts retaining the harness to the motor assembly and connector.
    Fig 8: Locating Bolts Retaining Harness To Motor Assembly & Connector
    GF0010650Courtesy of FORD MOTOR CO.
  9. Remove the rear shift motor bolt.
    Fig 9: Locating Rear Shift Motor Bolt
    GF0010651Courtesy of FORD MOTOR CO.
  10. Remove the front bolt and the motor assembly and connector.
    Fig 10: Locating Front Bolt On Motor Assembly & Connector
    GF0010652Courtesy of FORD MOTOR CO.
  11. Remove the bolts that retain the transfer case cover to the transfer case.
    Fig 11: Locating Transfer Case Bolts
    GF0010653Courtesy of FORD MOTOR CO.
  12. Remove the bolts that retain the transfer case to the transfer case cover.
    Fig 12: Locating Transfer Case Cover Bolts
    GF0010654Courtesy of FORD MOTOR CO.
    13. NOTE: Position the assembly so that the front of the transfer case is facing downward.
    Fig 13: Separating Transfer Case Cover From Transfer Case Using Breaker Bar
    GF0010655Courtesy 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 14: Locating Snap Ring On Bearing
    GF0010656Courtesy of FORD MOTOR CO.
  15. Using the special tools, remove the bearing.
    Fig 15: Identifying Special Tool For Removing Bearing
    GF0010657Courtesy of FORD MOTOR CO.
  16. Using the special tools, remove the needle bearing.
    Fig 16: Identifying Special Tool For Needle Bearing
    GF0010658Courtesy 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 17: Identifying Shift Collar Hub, Return Spring & Electric Shift Cam Assembly
    GF0010659Courtesy of FORD MOTOR CO.
  18. Remove the snap ring.
    Fig 18: Locating Snap Ring
    GF0010660Courtesy of FORD MOTOR CO.
  19. Remove the lockup hub and the sleeve return spring from the lockup collar.
    Fig 19: Locating Lockup Hub & Sleeve Return Spring
    GF0010661Courtesy of FORD MOTOR CO.
  20. Remove the snap ring and the spacer.
    Fig 20: Locating Snap Ring & Spacer
    GF0010662Courtesy of FORD MOTOR CO.
  21. Remove the drive chain, the driven sprocket, and the drive sprocket as an assembly.
    Fig 21: Removing Drive Chain, Driven Sprocket & Drive Sprocket
    GF0010663Courtesy of FORD MOTOR CO.
  22. Remove the magnet and the oil strainer from the slot in the transfer case.
    Fig 22: Locating Magnet & Oil Strainer On Slot In Transfer Case
    GF0010664Courtesy of FORD MOTOR CO.
  23. Remove the rear output shaft and the pump assembly as an assembly.
    Fig 23: Removing Rear Output Shaft & Pump Assembly
    GF0010665Courtesy 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 24: Locating Alignment Key
    GF0010666Courtesy of FORD MOTOR CO.
    25. 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 25: Identifying Pump Drive Pin Height & Rear Output Shaft Diameter
    GF0010667Courtesy 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.
    26. CAUTION: Do not let the front output shaft assembly fall out of the case while removing the snap ring.
    Fig 26: Identifying Snap Ring On Front Output Shaft Assembly
    GF0010668Courtesy 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 27: Identifying Front Output Shaft Assembly
    GF0010669Courtesy of FORD MOTOR CO.
  28. Remove the reduction fork assembly and the reduction hub as an assembly.
    Fig 28: Identifying Reduction Fork Assembly & Reduction Hub
    GF0010670Courtesy of FORD MOTOR CO.
  29. Remove the 6 bolts retaining the front adapter assembly to the case.
    Fig 29: Identifying Bolts Retaining Front Adapter Assembly
    GF0010671Courtesy of FORD MOTOR CO.
  30. Remove the front adapter assembly, the input shaft assembly, and the complete carrier assembly as an assembly.
    Fig 30: Removing Front Adapter Assembly, Input Shaft Assembly & Complete Carrier Assembly
    GF0010672Courtesy 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 31: Identifying Complete Carrier Assembly & Input Shaft Assembly
    GF0010673Courtesy of FORD MOTOR CO.
  32. Remove the large snap ring from the front adapter.
    Fig 32: Locating Large Snap Ring From Front Adapter
    GF0010674Courtesy of FORD MOTOR CO.
  33. Using a suitable tool, remove the oil seal from the front adapter.
    Fig 33: Locating Oil Seal
    GF0010675Courtesy of FORD MOTOR CO.
  34. Remove the snap ring.
    Fig 34: Locating Snap Ring
    GF0010676Courtesy of FORD MOTOR CO.
  35. Using the special tool and a suitable press, remove the bearing.
    Fig 35: Removing Bearing Using Special Tool
    GF0010677Courtesy of FORD MOTOR CO.
  36. Remove the thrust washer and the input shaft assembly.
    Fig 36: Locating Thrust Washer & Input Shaft Assembly
    GF0010678Courtesy of FORD MOTOR CO.
  37. Remove the snap ring, the thrust plate, and the sun gear.
    Fig 37: Locating Snap Ring, Thrust Plate & Sun Gear
    GF0010679Courtesy of FORD MOTOR CO.
    38. NOTE: Remove and discard both the sleeve bearing and the needle bearing if either one is worn/damaged.
    Fig 38: Identifying Special Press Tool
    GF0010680Courtesy 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 39: Removing Oil Seal Using Special Tool
    GF0010681Courtesy of FORD MOTOR CO.
  40. Remove the snap ring retaining the bearing to the case.
    Fig 40: Removing Snap Ring Retaining Bearing To Case
    GF0010682Courtesy of FORD MOTOR CO.
  41. Using the special tools, remove the bearing.
    Fig 41: Identifying Special Bearing Removal Tool
    GF0010683Courtesy of FORD MOTOR CO.
  42. Using a suitable tool, remove the oil seal.
    Fig 42: Removing Oil Seal Using Special Tool
    GF0010684Courtesy of FORD MOTOR CO.
  43. Remove the shift fork facings.
    Fig 43: Locating Shift Fork Facings
    GF0010685Courtesy of FORD MOTOR CO.
  44. Remove the electric shift cam from the shift shaft.
    Fig 44: Locating Electric Shift Cam
    GF0010686Courtesy of FORD MOTOR CO.
    45. WARNING: Keep fingers away from spring ends. Failure to follow these instructions can result in personal injury.
    Fig 45: Locating Torsion Spring & Spacer
    GF0010687Courtesy of FORD MOTOR CO.
  45. Remove the torsion spring and the spacer from the shift shaft.
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