Transfer Case - Electronic Shift: Disassembly

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Discard all nuts, bolts and retaining rings after removing them from the transfer case. Install all new fasteners during transfer case assembly.

Attach the transfer case to the special tool.

Fig 1: Using Special Tool On Transfer Case
Courtesy of FORD MOTOR CO.
Remove the gearmotor encoder assembly.

Fig 2: Removing Gearmotor Encoder Assembly
Courtesy of FORD MOTOR CO.

CAUTION: Do not use air tools to remove the plugs.

Fig 3: Locating Drain And Fill Plugs

G04651015

Courtesy of FORD MOTOR CO.

Remove the drain and fill plugs.
Remove and discard the front output nut.
- Use the special tool to prevent the flange from turning.
  
  Fig 4: Removing Front Output Nut
  Courtesy of FORD MOTOR CO.
Using a suitable 2- or 3-jaw puller, remove the flange.

Fig 5: Locating Flange
Courtesy of FORD MOTOR CO.
Remove and discard the rear output nut.
- Use the special tool to prevent the flange from turning.
  
  Fig 6: Removing Rear Output Nut
  Courtesy of FORD MOTOR CO.
Using a suitable 2- or 3-jaw puller, remove the flange.

Fig 7: Locating Flange
Courtesy of FORD MOTOR CO.
Remove the slinger from the front flange and the rear flange, if necessary.

Fig 8: Locating Slinger From Front Flange And Rear Flange
Courtesy of FORD MOTOR CO.
Using the special tools, remove the rear output seal.

Fig 9: Using Special Tool On Rear Output Seal
Courtesy of FORD MOTOR CO.
Remove and discard the 8 rear retainer bolts.

Fig 10: Locating Rear Retainer Bolts
Courtesy of FORD MOTOR CO.
Using the special tool, separate the rear retainer from the rear case and remove the rear retainer.

Fig 11: Using Special Tool On Rear Retainer
Courtesy of FORD MOTOR CO.
Using the special tools and a suitable press, remove the needle bearing.

Fig 12: Using Special Tool On Needle Bearing
Courtesy of FORD MOTOR CO.
Disconnect the oil tube and remove the oil pump assembly.

Fig 13: Locating Oil Pump Assembly
Courtesy of FORD MOTOR CO.
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 14: Using Special Tool On Retaining Ring
    Courtesy of FORD MOTOR CO.
Remove and discard the 25 case bolts.

Fig 15: Locating Case Bolts
Courtesy of FORD MOTOR CO.
Using the special tool, separate the case halves and remove the rear case.

Fig 16: Using Special Tool On Case Halves
Courtesy of FORD MOTOR CO.
Remove the oil tube.

Fig 17: Locating Oil Tube
Courtesy of FORD MOTOR CO.
Remove the ball bearing retaining ring.

Fig 18: Locating Ball Bearing Retaining Ring
Courtesy of FORD MOTOR CO.
Using the special tools and a suitable press, remove the ball bearing.

Fig 19: Using Special Tool On Ball Bearing
Courtesy of FORD MOTOR CO.
Using the special tool, remove the needle bearing.

Fig 20: Using Special Tool On Needle Bearing
Courtesy of FORD MOTOR CO.
Remove the chip collector magnet.

Fig 21: Locating Chip Collector Magnet
Courtesy of FORD MOTOR CO.
Remove the driven sprocket retaining ring.

Fig 22: Locating Driven Sprocket Retaining Ring
Courtesy of FORD MOTOR CO.
Remove the drive sprocket retaining ring.

Fig 23: Locating Drive Sprocket Retaining Ring
Courtesy of FORD MOTOR CO.
Remove the mode spring.

Fig 24: Locating Mode Spring
Courtesy of FORD MOTOR CO.
Remove the drive sprocket, driven sprocket and the drive chain as an assembly.

Fig 25: Removing Drive Sprocket
Courtesy of FORD MOTOR CO.
Remove the mainshaft and the mode fork as an assembly.

Fig 26: Removing Mainshaft And Mode Fork Assembly
Courtesy of FORD MOTOR CO.
Slide the mode fork and synchronizer sleeve off the mainshaft, and separate the components.

Fig 27: Locating Mode Fork And Synchronizer Sleeve Off Mainshaft
Courtesy of FORD MOTOR CO.
Place the mainshaft in a soft-jawed vise with the threaded end upward.
Remove the clutch gear.

Fig 28: Removing Clutch Gear
Courtesy of FORD MOTOR CO.
Remove the retaining ring and the synchronizer hub.

Fig 29: Locating Retaining Ring And Synchronizer Hub
Courtesy of FORD MOTOR CO.
Remove the outer ring.

Fig 30: Locating Outer Ring
Courtesy of FORD MOTOR CO.
Remove the middle ring.

Fig 31: Locating Middle Ring
Courtesy of FORD MOTOR CO.
Remove the inner ring.

Fig 32: Locating Inner Ring
Courtesy of FORD MOTOR CO.
Remove the drive sprocket hub.

Fig 33: Locating Drive Sprocket Hub
Courtesy of FORD MOTOR CO.
Inspect all of the components for wear and damage.
Inspect the mode fork pads for wear.

Fig 34: Locating Mode Fork Pads For Wear
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 35: Locating Range Fork Assembly And Range Shift Sleeve

G04651047

Courtesy of FORD MOTOR CO.

Remove the range fork assembly and the range shift sleeve.

NOTE: Manual shift range fork shown, electric shift range fork similar.

Fig 36: Locating Manual Shift Range Fork

G04651048

Courtesy of FORD MOTOR CO.

Inspect the range fork pads for wear. If the pads are worn, discard the range fork, the pads, the mainshaft and the sleeve.
Using the special tools, remove the input seal.

Fig 37: Using Special Tool On Input Seal
Courtesy of FORD MOTOR CO.
Remove and discard the retaining ring.
1. Install the special tool.
2. Remove and discard the retaining ring.
  - Remove the special tool.
    
    Fig 38: Using Special Tool On Retaining Ring
    Courtesy of FORD MOTOR CO.
Remove the planetary assembly.

Fig 39: Locating Planetary Assembly
Courtesy of FORD MOTOR CO.
Remove the input bearing retaining ring.

Fig 40: Locating Input Bearing Retaining Ring
Courtesy of FORD MOTOR CO.
Using the special tool and a suitable press, remove the front input bearing.

Fig 41: Using Special Tool On Front Input Bearing
Courtesy of FORD MOTOR CO.
Using the special tools, remove the front output seal.

Fig 42: Using Special Tool On Front Output Seal
Courtesy of FORD MOTOR CO.
Remove and discard the retaining ring.
1. Install the special tool.
2. Remove and discard the retaining ring.
  
  Fig 43: Using Special Tool On Retaining Ring
  Courtesy of FORD MOTOR CO.
Remove the special tool and the front output shaft.

Fig 44: Using Special Tool On Front Output Shaft
Courtesy of FORD MOTOR CO.
Remove the front output ball bearing retaining ring.

Fig 45: Locating Front Output Ball Bearing Retaining Ring
Courtesy of FORD MOTOR CO.
Using the special tools and a suitable press, remove the front output ball bearing.

Fig 46: Using Special Tool On Front Output Ball Bearing
Courtesy of FORD MOTOR CO.
Remove the lock plate retaining ring.

Fig 47: Locating Lock Plate Retaining Ring
Courtesy of FORD MOTOR CO.
Lift out the input gear.
- Inspect the input gear for wear or damage. Install a new gear if necessary.
  
  Fig 48: Locating Input Gear
  Courtesy of FORD MOTOR CO.
Remove the lock plate.

Fig 49: Locating Lock Plate
Courtesy of FORD MOTOR CO.
Remove the front input gear thrust washer.

Fig 50: Locating Front Input Gear Thrust Washer
Courtesy of FORD MOTOR CO.
Remove the rear input gear thrust washer.

Fig 51: Locating Rear Input Gear Thrust Washer
Courtesy of FORD MOTOR CO.
Inspect the gear teeth and thrust washers for wear and damage. Install a new planetary gear assembly, if necessary.

Fig 52: Locating Planetary Gear Assembly
Courtesy of FORD MOTOR CO.
Remove the poppet assembly.

Fig 53: 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 54: Locating Poppet Screw, Spring And Poppet

G04651066

Courtesy of FORD MOTOR CO.

Disassemble the poppet screw, the spring and the poppet.
Remove the plastic retainer and the O-ring, and remove the sector assembly.

Fig 55: Locating Sector Assembly
Courtesy of FORD MOTOR CO.
Using the special tool, remove the motor adapter.

Fig 56: Using Special Tool On Motor Adapter
Courtesy of FORD MOTOR CO.
Remove and discard the support O-ring seal.

Fig 57: Locating Support O-Ring Seal
Courtesy of FORD MOTOR CO.