Transfer Case - (Torque On Demand (TOD)): Disassembly

WARNING: This page is about a different car, the 2007 Lincoln Mark LT and 2007 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: Wear protective eyewear whenever using compressed air.

Clean the transfer case with solvent and dry with compressed air.

WARNING: Make sure the special tool lock pin is secure.

Fig 1: Securing Transfer Case To Bench

GF0004137

Courtesy of FORD MOTOR CO.

Using the special tool, secure the transfer case to the bench.
If not done previously, remove the drain plug and drain the fluid.
- DRAIN fluid and INSPECT for contamination. If heavy metallic or plastic contamination is noted, REMOVE transfer case and INSPECT for source of contamination. INSTALL a new components as necessary.
Fig 2: Locating Drain Plug
Courtesy of FORD MOTOR CO.
Remove the coil wire electrical connector.
- Remove the wire connector spacer.
- Using an electrical connector pin extractor tool, remove the coil wire and pin.
Fig 3: Locating Coil Wire Electrical Connector
Courtesy of FORD MOTOR CO.
Install a 102 mm (4.0 in) piece of 31.75 mm (1.25 in) i.d. conduit on the output shaft into the extension housing to protect it from damage and keep the bushing from separating from the housing. Remove the 6 extension housing bolts.

Fig 4: Removing Housing Bolts
Courtesy of FORD MOTOR CO.
Using a soft faced hammer, tap the extension housing to break the gasket seal and remove the extension housing.
- If the extension housing bushing is dislodged during removal, a new extension housing bushing must be installed.
Fig 5: Removing Extension Housing
Courtesy of FORD MOTOR CO.
Remove the 3 coil-to-cover nuts and the coil.

Fig 6: Removing Coil-To-Cover Nuts And Coil
Courtesy of FORD MOTOR CO.
Remove the rear output shaft snap ring.

Fig 7: Locating Rear Output Shaft Snap Ring
Courtesy of FORD MOTOR CO.

NOTE: The bolts are self-tapping, and it is normal to find metal shavings while removing the cover.

Fig 8: Locating Case Bolts

GF0004143

Courtesy of FORD MOTOR CO.

Remove the case bolts.

NOTE: Use pry bosses to separate the cover from the case.

Fig 9: Locating Transfer Case Covers

GF0004144

Courtesy of FORD MOTOR CO.

Using a suitable pry bar, separate the transfer case covers.
Remove the bearing.

Fig 10: Locating Bearing
Courtesy of FORD MOTOR CO.
Remove the inboard bearing snap ring.

Fig 11: Locating Inboard Bearing Snap Ring
Courtesy of FORD MOTOR CO.
Remove the coil housing and thrust washer assembly.

Fig 12: Removing Coil Housing And Thrust Washer Assembly
Courtesy of FORD MOTOR CO.
Remove the 3 bearings and the apply cam.

Fig 13: Locating Bearings And Cam
Courtesy of FORD MOTOR CO.
Remove the wave spring.

Fig 14: Locating Wave Spring
Courtesy of FORD MOTOR CO.
Remove the snap ring.

Fig 15: Locating Snap Ring
Courtesy of FORD MOTOR CO.
Remove the clutch pack assembly.

Fig 16: Locating Clutch Pack Assembly
Courtesy of FORD MOTOR CO.
Remove the spacer.

Fig 17: Locating Spacer
Courtesy of FORD MOTOR CO.
Remove the drive chain and sprockets as an assembly.

Fig 18: Locating Drive Chain And Sprockets
Courtesy of FORD MOTOR CO.
Remove the magnet from its slot in the case.

Fig 19: Identifying Magnet
Courtesy of FORD MOTOR CO.
Remove the thrust bearing race.

Fig 20: Locating Thrust Bearing Race
Courtesy of FORD MOTOR CO.
Remove the thrust bearing.

Fig 21: Locating Thrust Bearing
Courtesy of FORD MOTOR CO.
Remove the thrust bearing race.

Fig 22: Locating Thrust Bearing Race
Courtesy of FORD MOTOR CO.
Remove the output shaft hub.

Fig 23: Locating Output Shaft Hub
Courtesy of FORD MOTOR CO.
Remove the oil pump and inlet tube.

Fig 24: Locating Oil Pump And Inlet Tube
Courtesy of FORD MOTOR CO.
Remove the output shaft.

Fig 25: Locating Output Shaft
Courtesy of FORD MOTOR CO.
Remove the input gear.

Fig 26: Locating Input Gear
Courtesy of FORD MOTOR CO.
Remove the snap ring.
Remove the input shaft support bearing.
Remove the input seal.
Remove the snap ring and the front output shaft.

Fig 27: Locating Snap Ring And Front Output Shaft
Courtesy of FORD MOTOR CO.
Using 2 crow's foot prybars, remove the front output shaft bearing.

Fig 28: Removing Front Output Shaft Bearing
Courtesy of FORD MOTOR CO.
Remove the front output shaft seal.

Fig 29: Locating Front Output Shaft Seal
Courtesy of FORD MOTOR CO.
Remove the dust shield, if necessary.

Fig 30: Removing Dust Shield
Courtesy of FORD MOTOR CO.