LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1873 (Transfer Case - F-150 & Mark LT) >> Disassembly And Assembly >> Transfer Case - Electronic Shift >> Disassembly

Transfer Case - Electronic Shift: 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.
CAUTION: Discard all seals after removing them.
  1. Remove the transfer case. For additional information, refer to Transfer Case - Electronic Shift  in this article.
    2. WARNING: Wear protective eyewear whenever using compressed air.
  2. Clean the transfer case with solvent and dry with compressed air.
    3. WARNING: Make sure the special tool lock pin is secure.
    Fig 1: Securing Transfer Case To Bench Using Special Tool
    GF0004063Courtesy of FORD MOTOR CO.
  3. Using the special tool, secure the transfer case to the bench.
  4. If not done previously, remove the drain plug and drain the fluid.
    Fig 2: Locating Drain Plug
    GF0004065Courtesy of FORD MOTOR CO.
  5. Review the transfer case symptom chart before and during the disassembly procedure.
    ELECTRONIC SHIFT TRANSFER CASE SYMPTOM CHART

    Condition Possible Source(s) Action
    Fluid contaminated (plastic/metallic)
    • Seal failure (items 23, 27, 49, 56).
    • Oil pump assembly (item 8).
    		 INSPECT seals for signs of ingress or egress. If metal and plastic contamination is noted when the fluid is drained, OPEN transfer case and INSPECT internal components for wear. INSTALL new components as necessary, including the transfer case pump. VERIFY correct operation of all components prior to reassembly. All contamination should be cleaned from the components. All bearings should be inspected for smooth operation.
    Jumps out of four wheel drive (4WD) (even when shift motor removed)
    • Lockup fork (item 65).
    • Reduction shift fork assembly (item 66).
    • Shift cam assembly (item 62).
    • Lockup hub assembly (item 12).
    • Oil pump assembly (item 8).
    		 INSPECT internal shift system for damage or wear. Shift forks and shift fork pads should be inspected for wear or damage. If signs of heat generation are noted, INSTALL a new pump assembly and INSTALL pump filter. INSPECT slip yokes and bushings for unusual wear.
    4HI will not engage (when shift cam is positioned manually in 4H with shift motor removed)
    • Transfer case shift components:
      • Lockup fork (item 65).
      • Lockup hub assembly (item 12).
      • Shift cam assembly (item 62).
      • Reduction shift fork assembly (item 66).
    • Oil pump assembly (item 8).
    		 INSPECT internal shift components for wear. Shift forks and shift fork pads should be inspected for wear or damage. If signs of heat generation are noted, INSTALL a new pump assembly and INSTALL pump filter. INSPECT slip yokes and bushings for unusual wear.
    4LO will not engage (when shift cam is positioned manually in 4L with shifter linkage removed)
    • Lockup fork (item 65).
    • Reduction shift fork assembly (item 66).
    • Reduction hub assembly (item 7).
    • Shift cam assembly (item 62).
    • Lockup hub assembly (item 12).
    • Oil pump assembly (item 8).
    		 INSPECT internal shift components for wear. Shift forks and shift fork pads should be inspected for wear or damage. If signs of heat generation are noted, INSTALL a new pump assembly and INSTALL pump filter. INSPECT slip yokes and bushings for unusual wear.
    4WD will not disengage (when shift cam is positioned manually in 2H with shifter motor removed)
    • Transfer case shift components:
      • Lockup fork (item 64).
      • Lockup Hub assembly (item 12).
      • Shift cam assembly (item 62).
      • Reduction shift fork assembly (item 66).
    • Oil pump assembly (item 8).
    		 INSPECT internal shift components for wear. Shift forks and shift fork pads should be inspected for wear or damage. If signs of heat generation are noted, INSTALL a new pump assembly and INSTALL pump filter. INSPECT slip yokes and bushings for unusual wear.
    Not able to manually shift transfer case
    • Transfer case shift components:
      • Lockup fork (item 65).
      • Lockup hub assembly (item 12).
      • Shift cam assembly (item 62).
      • Reduction shift fork assembly (item 66).
    • Oil pump assembly (item 8).
    		 INSPECT internal shift components for wear. Shift forks and shift fork pads should be inspected for wear or damage. If signs of heat generation are noted, INSTALL a new pump assembly and install pump filter. INSPECT slip yokes and bushings for unusual wear.
    NVH
    • Loose driveshafts.
    • Loose screws or bolts.
    • Drive chain (item 20).
    • Front planet carrier (item 4).
    • Shift components.
    		 INSPECT system for loose screws or bolts. TIGHTEN as required. DRAIN fluid and INSPECT for contamination. If heavy metallic or plastic contamination noted, REMOVE transfer case and INSPECT for source of contamination. INSTALL a new components as necessary. If signs of heat generation are noted, INSTALL a new pump assembly and INSTALL pump filter. INSPECT driveshaft slip yoke and INSTALL new as required.
    Uncommanded shift
    • Transfer case shift components:
      • Lockup fork (item 65).
      • Lockup hub assembly (item 12).
      • Shift cam assembly (item 62).
      • Reduction shift fork assembly (item 66).
    • Shift fork pads worn:
      • Reduction hub assembly (item 7).
    		 INSPECT internal shift components for wear. Shift forks and shift fork pads should be inspected for wear or damage. If signs of heat generation are noted, INSTALL a new pump assembly and INSTALL pump filter. INSPECT slip yokes and bushings for unusual wear.
    Rear output leak
    • Yoke to flange seal (item 56).
    • Slip yoke damage or degradation.
    • Internal or external contamination.
    		 INSPECT yoke for damage or excessive wear. If wear noted on yoke, INSPECT transfer case rear output bushing for damage. INSPECT transfer case seal for damage or wear. INSPECT system for contamination. INSTALL a new slip yoke, transfer case bushing and/or seal as required.
    Transfer case overfull
    • Input flange seal (item 23).
    		 CHECK transmission for low fluid condition. If transmission fluid level OK, DRAIN and REFILL transfer case to correct level. If transmission fluid level low, INSPECT the input flange seal for damage.
    T-case is in a range/mode other than indicated by motor contact plates (uncommanded shift/jumps out of gear)
    • Transfer case shift components:
      • Lockup fork (item 65).
      • Lockup hub assembly (item 12).
      • Shift cam assembly (item 62).
      • Reduction shift fork assembly (item 66).
    • Oil pump assembly (item 8).
    		 INSPECT internal shift components for wear. Shift forks and shift fork pads should be inspected for wear or damage. If signs of heat generation are noted, INSTALL a new pump assembly and INSTALL pump filter. INSPECT slip yokes and bushings for unusual wear.
  6. Using a suitable tool, remove the oil seal.
    Fig 3: Removing Oil Seal
    GF0004127Courtesy of FORD MOTOR CO.
  7. Remove the coil wire and the ground wire from the electric shift motor electrical connector.
    • Remove the wire connector spacer.
    • Remove the coil wire and pin.
    • Remove the ground wire and pin.
      • Use an electrical connector pin extractor tool.
    Fig 4: Removing Coil Wire And Ground Wire From Electric Shift Motor Electrical Connector
    GF0004128Courtesy of FORD MOTOR CO.
  8. Remove the transfer case shift motor.
    1. Remove the bolts.
    2. Remove the transfer case shift motor.
      Fig 5: Identifying Transfer Case Shift Motor Bolts
      GF0004129Courtesy of FORD MOTOR CO.
  9. Remove the extension housing.
    1. Remove the 6 extension housing bolts.
    2. Remove the extension housing.
    Fig 6: Identifying Extension Housing Bolts
    GF0004130Courtesy of FORD MOTOR CO.
  10. Remove the rear output shaft snap ring.
    • Lift up on the output shaft while removing the snap ring.
    Fig 7: Removing Rear Output Shaft Snap Ring
    GF0004070Courtesy of FORD MOTOR CO.
    11. NOTE: The bolts are self-tapping, and it is normal to find metal shavings while removing the cover.
    Fig 8: Removing Transfer Case Bolts
    GF0004071Courtesy of FORD MOTOR CO.
  11. Remove the bolts.
    12. NOTE: Use pry bosses to separate the cover from the case.
    Fig 9: Separating Transfer Case Covers
    GF0004072Courtesy of FORD MOTOR CO.
  12. Separate the transfer case covers.
  13. Remove the coil.
    1. Remove the 3 coil-to-cover nuts.
    2. Remove the coil.
    Fig 10: Removing Coil-To-Cover Nuts
    GF0004073Courtesy of FORD MOTOR CO.
  14. Using the special tools, remove the rear output shaft bearing.
    Fig 11: Removing Rear Output Shaft Bearing Using Special Tools
    GF0004074Courtesy of FORD MOTOR CO.
  15. Using the special tools, remove the front output shaft bearing.
    Fig 12: Removing Front Output Shaft Bearing Using Special Tools
    GF0004075Courtesy of FORD MOTOR CO.
  16. Remove the shift collar hub snap ring.
    Fig 13: Removing Shift Collar Hub Snap Ring
    GF0004076Courtesy of FORD MOTOR CO.
  17. Remove the coil housing.
    Fig 14: Removing Coil Housing
    GF0004077Courtesy of FORD MOTOR CO.
  18. Remove the shift fork.
    1. Remove the lockup hub.
    2. Remove the shift fork and spring.
    Fig 15: Removing Shift Fork
    GF0004078Courtesy of FORD MOTOR CO.
    19. NOTE: Remove the lockup hub assembly as a single unit. If disassembly is required, proceed with the following.
    Fig 16: Disassembling Lockup Hub Assembly
    GF0004079Courtesy of FORD MOTOR CO.
  19. Disassemble the lockup hub assembly.
    1. Remove the lockup hub snap ring.
    2. Separate the lockup collar.
    3. Separate the 2 lockup springs.
    4. Separate the lockup hub.
    5. Remove the armature.
  20. Remove the spacer.
    Fig 17: Removing Spacer
    GF0004080Courtesy of FORD MOTOR CO.
  21. Remove the drive chain and sprockets as an assembly.
    Fig 18: Removing Drive Chain And Sprockets
    GF0004081Courtesy of FORD MOTOR CO.
  22. Remove the magnet from its slot in the case.
    Fig 19: Identifying Magnet
    GF0004082Courtesy of FORD MOTOR CO.
    23. NOTE: The pump assembly is not repairable.
    Fig 20: Removing Oil Pump And Output Shaft
    GF0004083Courtesy of FORD MOTOR CO.
  23. Remove the oil pump and the output shaft as an assembly.
    • Remove the oil pump from the output shaft.
  24. Remove the shift rail.
    Fig 21: Removing Shift Rail
    GF0004084Courtesy of FORD MOTOR CO.
  25. Remove the shift fork and the reduction hub.
    1. Remove the shift fork.
    2. Remove the reduction hub.
    Fig 22: Removing Shift Fork And Reduction Hub
    GF0004085Courtesy of FORD MOTOR CO.
    26. WARNING: Do not disassemble shift cam assembly.
    Fig 23: Removing Electric Shift Cam Assembly
    GF0004131Courtesy of FORD MOTOR CO.
  26. Remove the electric shift cam assembly.
  27. Using the special tool, remove the input seal.
    Fig 24: Removing Input Seal
    GF0004086Courtesy of FORD MOTOR CO.
    28. CAUTION: Do not let the front planet carrier fall while removing the snap ring.
    Fig 25: Removing Front Planet Carrier
    GF0004087Courtesy of FORD MOTOR CO.
  28. Remove the front planet carrier.
    1. Remove the front planet carrier snap ring.
    2. Remove the front planet carrier.
  29. If necessary, using the special tools, remove the bushing from the front planet.
    Fig 26: Removing Bushing From Front Planet Using Special Tools
    GF0004088Courtesy of FORD MOTOR CO.
  30. Using a drift and a hammer, remove the needle bearing, if necessary.
    Fig 27: Removing Needle Bearing
    GF0004089Courtesy of FORD MOTOR CO.
  31. Remove the ring gear.
    1. Remove the ring gear snap ring.
    2. Remove the ring gear.
    Fig 28: Removing Ring Gear
    GF0004090Courtesy of FORD MOTOR CO.
  32. Remove the front planet carrier bearing snap ring. Then, using the special tools, remove the front planet carrier bearing.
    Fig 29: Removing Front Planet Carrier Bearing Snap Ring
    GF0004091Courtesy of FORD MOTOR CO.
    33. CAUTION: Do not let the front output shaft fall while removing the snap ring.
    Fig 30: Removing Front Output Shaft
    GF0004092Courtesy of FORD MOTOR CO.
  33. Remove the front output shaft.
    1. Remove the front output shaft snap ring.
    2. Remove the front output shaft.
  34. Using the special tools, remove the front output shaft bearing.
    Fig 31: Removing Front Output Shaft Bearing
    GF0004093Courtesy of FORD MOTOR CO.
  35. Using the special tools, remove the front yoke to flange seal.
    Fig 32: Removing Front Yoke To Flange Seal
    GF0004094Courtesy of FORD MOTOR CO.
  36. Using a suitable pry tool, remove the electric shift motor seal.
    Fig 33: Removing Electric Shift Motor Seal
    GF0004132Courtesy of FORD MOTOR CO.
  37. Remove the dust shield, if necessary.
    Fig 34: Removing Dust Shield
    GF0004098Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals