Transfer Case Model 4405: Disassembly

Remove transfer case. See REMOVAL & INSTALLATION . Remove rear output flange lock nut, flat washer, rubber seal and yoke. Remove front output flange lock nut, flat washer, rubber seal and yoke.
Remove the necessary wires from transfer case harness connector by removing terminal lock from rear of harness connector. Remove shift motor, noting position of triangular shaft in case and slot in motor.
Remove speed sensors from case. Remove case-to-cover bolts and pry front case and rear cover apart. Ensure rear cover is facing up. If speedometer drive gear or ball bearing assembly is to be replaced, remove rear output shaft oil seal. Remove internal snap ring and drive bearing assembly from outside case.
If required, remove front output shaft caged needle bearing snap ring and drive bearing out of rear cover. Remove 3 nuts and clutch coil assembly, "O" rings and Brown wire from case.
Remove output shaft bearing, coil housing, balls, apply cam and wave spring from output shaft. See Fig 1 . Remove chain with sprockets together. Remove thrust washer from output shaft.

Fig 1: Exploded View Of Coil Housing & Cam Assembly
Courtesy of FORD MOTOR CO.
Remove oil pan magnet. Remove output shaft with oil pump. If removal of oil pump from output shaft is required, DO NOT use excessive force. Pull out shift rail. Remove helical cam assembly from case. If required, remove helical cam, torsion spring and sleeve from helical cam shaft from front case.
Remove high-low shift fork and collar as an assembly. Expand the tangs of large snap ring. Push case down and slide main drive gear bearing retainer off bearing. Remove oil seal from case by prying curved lip of oil seal. Use caution not to damage case.
Remove internal snap ring from planetary carrier and separate front planet from input shaft. Remove external snap ring from input shaft. See Fig 2 . Using a bearing splitter and press, remove thrust washer, thrust plate and sun gear off input shaft

Fig 2: Exploded View Of Input Shaft Components
Courtesy of FORD MOTOR CO.

NOTE: Under normal use, input shaft needle bearing and bushing should not require replacement. If replacement is required, replace bushing and bearing as a set.
Replace needle bearing and bushing (if necessary) using a press and appropriate arbor. Press bearing and bushing together from input shaft. To install bearing and bushing, reverse removal procedure.
Remove front yoke flange seal. If necessary, remove internal snap ring retaining front output shaft ball bearing. Remove bearing using bearing splitter and drift.