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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1031 (Transfer Case -- F150 Pickup) >> Disassembly And Assembly >> Transfer Case - Electronic Shift >> Disassembly

Transfer Case - Electronic Shift: Disassembly

WARNING: This page is about a different car, the 2005 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 .
    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
    G03964850Courtesy 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: Removing Drain Plug
    G03949508Courtesy 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. If issue not resolved, CONTACT Service Hotline for direction.
    • Jumps out of 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. If issue not resolved, CONTACT Service Hotline for direction.
    • 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. If issue not resolved, CONTACT Service Hotline for direction.
    • 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. If issue not resolved, CONTACT Service Hotline for direction.
    • 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. If issue not resolved, CONTACT Service Hotline for direction.
    • 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. If issue not resolved, CONTACT Service Hotline for direction.
    • 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. If issue not resolved, CONTACT Service Hotline for direction.
    • 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. If issue not resolved, CONTACT Service Hotline for direction.
    • 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. If issue not resolved, CONTACT Service Hotline for direction.
    • 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. If issue not resolved, CONTACT Service Hotline for direction.
    • 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. If issue not resolved, CONTACT Service Hotline for direction.
  6. Using a suitable tool, remove the oil seal.
    Fig 3: Removing Oil Seal Using Suitable Tool
    G03964852Courtesy 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
    G03964853Courtesy of FORD MOTOR CO.
  8. Remove the transfer case shift motor.
    1. Remove the bolts.
    2. Remove the transfer case shift motor.
    Fig 5: Removing Transfer Case Shift Motor
    G03964854Courtesy of FORD MOTOR CO.
  9. Remove the extension housing.
    1. Remove the 6 extension housing bolts.
    2. Remove the extension housing.
    Fig 6: Removing Extension Housing Bolts
    G03964855Courtesy 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: Lifting Up On Output Shaft While Removing Snap Ring
    G03964856Courtesy 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 Bolts
    G03964857Courtesy 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
    G03964858Courtesy 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
    G03964859Courtesy 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
    G03964860Courtesy 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
    G03964861Courtesy of FORD MOTOR CO.
  16. Remove the shift collar hub snap ring.
    Fig 13: Removing Shift Collar Hub Snap Ring
    G03964947Courtesy of FORD MOTOR CO.
  17. Remove the coil housing.
    Fig 14: Removing Coil Housing
    G03964863Courtesy 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
    G03964864Courtesy 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
    G03964865Courtesy 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
    G03964866Courtesy of FORD MOTOR CO.
  21. Remove the drive chain and sprockets as an assembly.
    Fig 18: Removing Drive Chain And Sprockets As An Assembly
    G03964867Courtesy of FORD MOTOR CO.
  22. Remove the magnet from its slot in the case.
    Fig 19: Removing Magnet From Its Slot In Case
    G03934095Courtesy of FORD MOTOR CO.
    23. NOTE: The pump assembly is not repairable.
    Fig 20: Removing Oil Pump And Output Shaft As An Assembly
    G03964869Courtesy 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
    G03964870Courtesy 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
    G03964871Courtesy of FORD MOTOR CO.
    26. WARNING: Do not disassemble shift cam assembly.
    Fig 23: Removing Electric Shift Cam Assembly
    G03964872Courtesy 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 Using Special Tool
    G03964873Courtesy 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 Snap Ring And Front Planet Carrier
    G03964874Courtesy 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
    G03964875Courtesy of FORD MOTOR CO.
  30. Using a drift and a hammer, remove the needle bearing, if necessary.
    Fig 27: Removing Needle Bearing
    G03964960Courtesy 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
    G03964961Courtesy 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: Using Special Tools To Remove Front Planet Carrier Bearing
    G03964878Courtesy 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
    G03964879Courtesy 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: Using Special Tools To Remove Front Output Shaft Bearing
    G03964880Courtesy of FORD MOTOR CO.
  35. Using the special tools, remove the front yoke to flange seal.
    Fig 32: Using Special Tools To Remove Front Yoke To Flange Seal
    G03964881Courtesy of FORD MOTOR CO.
  36. Using a suitable pry tool, remove the electric shift motor seal.
    Fig 33: Using Suitable Pry Tool To Remove Electric Shift Motor Seal
    G03964882Courtesy of FORD MOTOR CO.
  37. Remove the dust shield, if necessary.
    Fig 34: Removing Dust Shield
    G03964883Courtesy of FORD MOTOR CO.
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