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Transfer Case: Disassembly

WARNING: This page is about a different variant/trim than selected.
    WARNING:
    1. Make sure protective eyewear is in place.
    2. Use a petroleum-based solvent to clean the transfer case. Refer to the solvent manufacturer's safety precautions to prevent personal injury or transfer case damage.
    CAUTION: Seal all openings before cleaning the transfer case exterior. This will prevent entry of dirt and water, which can cause damage to internal components.
  1. Clean the transfer case exterior with solvent and dry with compressed air.
  2. Using special tool 307-003, secure the transfer case to a work bench. Rotate the transfer case so that the output shaft is pointing upward.
  3. Drain the fluid from the transfer case, if not done previously.
  4. Using a suitable tool, remove and discard the oil seal.
    Fig 1: Locating Oil Seal
    G04628986Courtesy of FORD MOTOR CO.
  5. Remove the coil wire pin from the electrical connector.
    • Remove the wire connector spacer.
    • Remove the coil wire pin (tan wire).
      • Use an electrical connector pin extractor tool.
  6. Remove the bolts and transfer case shift motor.
  7. Remove the 3 coil nuts and washers.
    Fig 2: Locating Transfer Case Shift Motor Nuts
    G04628987Courtesy of FORD MOTOR CO.
    8. NOTE: It is normal to find metal shavings after removing the self-tapping transfer case bolts.
    Fig 3: Locating Transfer Case Bolts
    G04628988Courtesy of FORD MOTOR CO.
  8. Remove the 20 bolts.
  9. Separate the transfer case halves.
    • Use the pry bosses to separate the case halves.
      Fig 4: Locating Case Halves
      G04628989Courtesy of FORD MOTOR CO.
  10. Using the special tool, remove the rear output shaft support bearing.
    Fig 5: Locating Rear Output Shaft Support Bearing
    G04628990Courtesy of FORD MOTOR CO.
  11. Using the special tool, remove the front output shaft rear bearing.
    Fig 6: Locating Front Output Shaft Rear Bearing
    G04628991Courtesy of FORD MOTOR CO.
  12. Remove the snap ring.
    • Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
  13. Remove the caged thrust bearing assembly.
    • Inspect the bearing for wear or damage. Install a new bearing as necessary.
  14. Remove the cam/coil housing.
    Fig 7: Locating Cam/Coil Housing
    G04628992Courtesy of FORD MOTOR CO.
  15. Remove the steel balls and the cam.
    Fig 8: Locating Steel Balls & Cam
    G04628993Courtesy of FORD MOTOR CO.
  16. Remove the wave spring.
  17. Remove and discard the snap ring.
    Fig 9: Locating Snap Ring
    G04628994Courtesy of FORD MOTOR CO.
    18. CAUTION: When removing 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 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 10: Identifying Clutch Pack Assembly
    G04628995Courtesy of FORD MOTOR CO.
  18. Remove the clutch pack assembly.
  19. 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 11: Locating Drive Chain & Sprockets
      G04628996Courtesy of FORD MOTOR CO.
  20. 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 12: Identifying Thrust Bearing Assembly
        G04628997Courtesy of FORD MOTOR CO.
  21. Remove and clean the oil pan magnet.
    Fig 13: Removing Oil Pan Magnet
    G04628998Courtesy of FORD MOTOR CO.
  22. Remove the output shaft sprocket.
    Fig 14: Locating Output Shaft Sprocket
    G04628999Courtesy of FORD MOTOR CO.
  23. Remove the oil pump assembly.
    Fig 15: Locating Oil Pump Assembly
    G04629000Courtesy of FORD MOTOR CO.
  24. Remove the output shaft.
    Fig 16: Locating Output Shaft
    G04629001Courtesy of FORD MOTOR CO.
    25. WARNING: Do not disassemble the shift cam assembly.
  25. 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.
      Fig 17: Locating Reduction Hub & Reduction Shift Fork
      G04629002Courtesy of FORD MOTOR CO.
  26. Remove the shift fork shaft.
    Fig 18: Identifying Shift Fork Shaft
    G04629003Courtesy of FORD MOTOR CO.
  27. Remove the front planet.
    • Using a drift and a hammer, remove the front planet needle bearing, if necessary.
      Fig 19: Locating Front Planet Needle Bearing
      G04629004Courtesy of FORD MOTOR CO.
  28. 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 20: Identifying Ring Gear
      G04629005Courtesy of FORD MOTOR CO.
    29. CAUTION: Do not let the front output shaft fall when removing the snap ring.
  29. Remove the snap ring and the front output shaft.
    • Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
    30. NOTE: Carefully remove the seal, do not damage the seal bore.
    Fig 21: Locating Front Output Shaft Oil Seal
    G04629006Courtesy of FORD MOTOR CO.
  30. Remove and discard the front output shaft oil seal.
    31. NOTE: Carefully remove the seal, do not damage the seal bore.
    Fig 22: Locating Front Input Shaft Oil Seal
    G04629007Courtesy of FORD MOTOR CO.
  31. Remove and discard the front input shaft oil seal.
  32. Using a suitable driver, remove the front planet support bearing.
    Fig 23: Locating Front Planet Support Bearing
    G04629008Courtesy of FORD MOTOR CO.
  33. Using a suitable driver, remove the front output shaft support bearing.
    Fig 24: Locating Front Output Shaft Support Bearing
    G04629009Courtesy of FORD MOTOR CO.
  34. Using a suitable tool, remove and discard the shifter shaft seal.
    Fig 25: Locating Shifter Shaft Seal
    G04629010Courtesy of FORD MOTOR CO.
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