Transfer Case: Disassembly

All transfer cases 

1. Attach the transfer case to the special tool.
   Fig 1: Attaching Transfer Case To Special Tool

   Courtesy of FORD MOTOR CO.

   Electric shift transfer case 

2. Remove the gearmotor encoder assembly.
   Fig 2: Removing Gearmotor Encoder Assembly

   Courtesy of FORD MOTOR CO.

   Manual shift transfer case 

3. Remove the 3 position switch.
   Fig 3: Removing Position Switch

   Courtesy of FORD MOTOR CO.

   All transfer cases 

CAUTION: Do not use air tools to remove the plugs.
Fig 4: Removing Drain And Fill Plugs
Courtesy of FORD MOTOR CO.
4. Remove the drain and fill plugs.
5. Remove and discard the nut.
   • Use the special tool to prevent the flange from turning.
     Fig 5: Removing Nut

     Courtesy of FORD MOTOR CO.
6. Using a suitable 2- or 3-jaw puller, remove the flange.
   Fig 6: Removing Flange Using Special Tool

   Courtesy of FORD MOTOR CO.
7. Remove and discard the nut.
   • Use the special tool to prevent the flange from turning.
     Fig 7: Removing Nut

     Courtesy of FORD MOTOR CO.
8. Using a suitable 2- or 3-jaw puller, remove the flange.
   Fig 8: Removing Flange Using Special Tool

   Courtesy of FORD MOTOR CO.
9. Remove the slinger from the front flange and the rear flange, if necessary.
   Fig 9: Removing Slinger From Front Flange And Rear Flange

   Courtesy of FORD MOTOR CO.
10. Using the special tools, remove the rear output seal.
    Fig 10: Removing Rear Output Seal Using Special Tool

    Courtesy of FORD MOTOR CO.
11. Remove and discard the eight bolts retaining the rear retainer to the rear case.
    Fig 11: Removing Bolts Retaining Rear Retainer To Rear Case

    Courtesy of FORD MOTOR CO.
12. Remove the rear retainer.
    • Use the special tool to separate the rear retainer from the rear case.
      Fig 12: Removing Rear Retainer

      Courtesy of FORD MOTOR CO.
13. Using the special tools and a suitable press, remove the needle bearing.
    Fig 13: Removing Needle Bearing Using Special Tool

    Courtesy of FORD MOTOR CO.
14. Disconnect the oil tube and remove the oil pump assembly.
    Fig 14: Removing Oil Pump Assembly

    Courtesy of FORD MOTOR CO.
15. Remove and discard the retaining ring.
    1. Install the special tool.
    2. Lift up on the shaft, and remove and discard the retaining ring.
    • Remove the special tool.
      Fig 15: Removing Special Tool

      Courtesy of FORD MOTOR CO.
16. Remove and discard the 25 bolts retaining the rear case to the front case.
    Fig 16: Removing Bolts Retaining Rear Case To Front Case

    Courtesy of FORD MOTOR CO.
17. Remove the rear case.
    • Use the special tool to separate the case halves.
      Fig 17: Removing Rear Case

      Courtesy of FORD MOTOR CO.
18. Remove the oil tube.
    Fig 18: Removing Oil Tube

    Courtesy of FORD MOTOR CO.
19. Remove the ball bearing retaining ring.
    Fig 19: Removing Ball Bearing Retaining Ring

    Courtesy of FORD MOTOR CO.
20. Using the special tools and a suitable press, remove the ball bearing.
    Fig 20: Removing Ball Bearing Using Special Tool

    Courtesy of FORD MOTOR CO.
21. Using the special tool, remove the needle bearing.
    Fig 21: Removing Needle Bearing Using Special Tool

    Courtesy of FORD MOTOR CO.
22. Remove the chip collector magnet.
    Fig 22: Removing Chip Collector Magnet

    Courtesy of FORD MOTOR CO.
23. Remove the driven sprocket retaining ring.
    Fig 23: Removing Driven Sprocket Retaining Ring

    Courtesy of FORD MOTOR CO.
24. Remove the drive sprocket retaining ring.
    Fig 24: Removing Drive Sprocket Retaining Ring

    Courtesy of FORD MOTOR CO.
25. Remove the mode spring.
    Fig 25: Removing Mode Spring

    Courtesy of FORD MOTOR CO.
26. Remove the sprockets and chain as an assembly.
    Fig 26: Removing Sprockets And Chain Assembly

    Courtesy of FORD MOTOR CO.
27. Remove the mainshaft and the mode fork assembly as an assembly.
    Fig 27: Removing Mainshaft And Mode Fork Assembly

    Courtesy of FORD MOTOR CO.
28. Slide the mode fork and synchronizer sleeve off the mainshaft, and separate the components.
    • Mode sleeve for mechanical shift or synchronizer sleeve for electric shift.
      Fig 28: Sliding Mode Fork And Synchronizer Sleeve Off Mainshaft

      Courtesy of FORD MOTOR CO.
29. Place the mainshaft in a soft jawed vise with the threaded end upward.
30. Remove the clutch gear.
    Fig 29: Removing Clutch Gear

    Courtesy of FORD MOTOR CO.

    Mechanical shift transfer case 

31. Remove the mode hub.

    Electric shift transfer case 

32. Remove the retaining ring and the synchronizer hub.
    Fig 30: Removing Retaining Ring And Synchronizer Hub

    Courtesy of FORD MOTOR CO.
33. Remove the outer ring.
    Fig 31: Removing Outer Ring

    Courtesy of FORD MOTOR CO.
34. Remove the middle ring.
    Fig 32: Removing Middle Ring

    Courtesy of FORD MOTOR CO.
35. Remove the inner ring.
    Fig 33: Removing Inner Ring

    Courtesy of FORD MOTOR CO.

    All transfer cases 

36. Remove the drive sprocket hub.
    Fig 34: Removing Drive Sprocket Hub

    Courtesy of FORD MOTOR CO.
37. Inspect all of the components for wear and damage.
38. Inspect the mode fork pads for wear.
    Fig 35: Inspecting Mode Fork Pads

    Courtesy of FORD MOTOR CO.
NOTE: Manual shift range fork shown, electric shift range fork similar.
NOTE: Rotate the sector assembly to the 4-wheel high position for easy removal.
Fig 36: Removing Range Fork Assembly And Range Shift Sleeve
Courtesy of FORD MOTOR CO.
39. Remove the range fork assembly and the range shift sleeve.
NOTE: Manual shift range fork shown, electric shift range fork similar.
Fig 37: Inspecting Range Fork Pads
Courtesy of FORD MOTOR CO.
40. Inspect the range fork pads for wear. If the pads are worn, discard the range fork, the pads, the mainshaft, and the sleeve.
41. Using the special tools, remove the input seal.
    Fig 38: Removing Input Seal Using Special Tool

    Courtesy of FORD MOTOR CO.
42. Remove and discard the retaining ring.
    1. Install the special tool.
    2. Remove and discard the retaining ring.
    • Remove the special tool.
      Fig 39: Removing Special Tool

      Courtesy of FORD MOTOR CO.
43. Remove the planetary assembly.
    Fig 40: Removing Planetary Assembly

    Courtesy of FORD MOTOR CO.
44. Remove the input bearing retaining ring.
    Fig 41: Removing Input Bearing Retaining Ring

    Courtesy of FORD MOTOR CO.
45. Using the special tool and a suitable press, remove the front input bearing.
    Fig 42: Removing Front Input Bearing Using Special Tool

    Courtesy of FORD MOTOR CO.
46. Using the special tools, remove the front output seal.
    Fig 43: Removing Front Output Seal Using Special Tool

    Courtesy of FORD MOTOR CO.
47. Remove and discard the retaining ring.
    1. Install the special tool.
    2. Remove and discard the retaining ring.
       Fig 44: Removing Retaining Ring

       Courtesy of FORD MOTOR CO.
48. Remove the special tool and the front output shaft.
    Fig 45: Removing Special Tool And Front Output Shaft

    Courtesy of FORD MOTOR CO.
49. Remove the front output ball bearing retaining ring.
    Fig 46: Removing Front Output Ball Bearing Retaining Ring

    Courtesy of FORD MOTOR CO.
50. Using the special tools and a suitable press, remove the front output ball bearing.
    Fig 47: Removing Front Output Ball Bearing Using Special Tool

    Courtesy of FORD MOTOR CO.
51. Remove the lock plate retaining ring.
    Fig 48: Removing Lock Plate Retaining Ring

    Courtesy of FORD MOTOR CO.
52. Lift out the input gear.
    • Inspect the input gear for wear or damage. Install a new gear if necessary.
      Fig 49: Inspecting Input Gear

      Courtesy of FORD MOTOR CO.
53. Remove the lock plate.
    Fig 50: Removing Lock Plate

    Courtesy of FORD MOTOR CO.
54. Remove the front input gear thrust washer.
    Fig 51: Removing Front Input Gear Thrust Washer

    Courtesy of FORD MOTOR CO.
55. Remove the rear input gear thrust washer.
    Fig 52: Removing Rear Input Gear Thrust Washer

    Courtesy of FORD MOTOR CO.
56. Inspect the gear teeth and thrust washers for wear and damage. Discard the planetary gear assembly, if necessary.
    Fig 53: Inspecting Gear Teeth And Thrust Washers

    Courtesy of FORD MOTOR CO.
57. Remove the poppet assembly.
    Fig 54: Removing Poppet Assembly

    Courtesy of FORD MOTOR CO.
NOTE: If installing a new poppet spring, it must be like in color to the original poppet spring.
Fig 55: Disassembling Poppet Screw, Spring, And Poppet
Courtesy of FORD MOTOR CO.
58. Disassemble the poppet screw, the spring, and the poppet.

    Manual shift transfer case 

59. Remove the locknut, the washer, the lever, the spacer, and the sector assembly.
    Fig 56: Removing Locknut, Washer, Lever, Spacer, And Sector Assembly

    Courtesy of FORD MOTOR CO.

    Electric shift transfer case 

60. Remove the plastic retainer and the O-ring, and remove the sector assembly.
    Fig 57: Removing Sector Assembly

    Courtesy of FORD MOTOR CO.

    All transfer cases 

61. Using the special tool, remove the sector shaft support (motor adapter for electric shift transfer case).
    Fig 58: Removing Sector Shaft Support Using Special Tool

    Courtesy of FORD MOTOR CO.
62. Remove and discard the support O-ring seal.
    Fig 59: Removing Support O-Ring Seal

    Courtesy of FORD MOTOR CO.