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Transfer Case - Mechanical 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.
NOTE: Place the transfer case in the NEUTRAL position for disassembly.
  1. Remove the transfer case. For additional information, refer to Transfer Case - Mechanical 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. Remove the mode indicator switch.
    Fig 2: Identifying Mode Indicator Switch
    GF0004064Courtesy of FORD MOTOR CO.
  5. Using a suitable tool, remove the rear output shaft seal.
    Fig 3: Locating Rear Output Shaft Seal
    GF0004050Courtesy of FORD MOTOR CO.
  6. If not done previously, remove the drain plug and drain the fluid.
    Fig 4: Locating Drain Plug
    GF0004065Courtesy of FORD MOTOR CO.
  7. Review the transfer case symptom chart before and during the disassembly procedure.
    MECHANICAL SHIFT TRANSFER CASE SYMPTOM CHART

    Condition Possible Source(s) Action
    Fluid contaminated (plastic/metallic)
    • Seal failure (items 18, 28, 33, and 56).
    • Oil pump assembly (item 7).
    		 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 lever is not connected)
    • Lockup fork (item 71).
    • Reduction shift fork assembly (item 72).
    • Mechanical shift cam (item 20).
    • Detent spring (item 15).
    • Detent roller (item 16).
    • Lockup hub assembly (item 42).
    • Oil pump assembly (item 7).
    		 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 oil pump assembly and INSTALL pump filter. INSPECT slip yokes and bushings for unusual wear.
    Excessive grinding/clunk/effort when shifting in/out of 4LO (condition not improved with trans in Park)
    • Operator shifting through positions too slowly.
    • Vehicle shift linkage.
    • Transmission neutral drag.
    • Transfer case shift components:
      • Reduction shift fork assembly (item 72).
      • Mechanical shift cam (item 20).
      • Detent spring (item 15).
      • Detent roller (item 16).
      • Lockup hub assembly (item 42).
      • Oil pump assembly (item 7).
      • Reduction hub assembly (item 38).
    		 Put vehicle in NEUTRAL, accelerate to 2,000 rpm and ATTEMPT shift (the operator should move the shifter quickly without pausing). Shift effort should be smoother and less audible. (This action reduced transmission neutral drag.) If no difference noticed with increased rpm, INSPECT shift linkage and transfer case internal components for wear or damage.
    4HI will not engage (when shift cam positioned manually in 4H with shifter linkage removed)
    • Transfer case shift components:
      • Lockup fork (item 71).
      • Lockup hub assembly (item 42).
      • Mechanical shift cam (item 20).
      • Detent spring (item 15).
      • Detent roller (item 16).
      • Reduction shift fork assembly (item 72).
    • Oil pump 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 oil pump assembly and INSTALL pump filter. INSPECT slip yokes and bushings for unusual wear.
    4LO will not engage (when the shift cam is positioned manually in 4L with the shifter linkage removed)
    • Lockup fork (item 71).
    • Reduction shift fork assembly (item 72).
    • Reduction hub assembly (item 38).
    • Mechanical shift cam (item 20).
    • Detent spring (item 15).
    • Detent roller (item 16).
    • Lockup hub assembly (item 42).
    • Oil pump 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 oil pump assembly and INSTALL pump filter. INSPECT slip yokes and bushings for unusual wear.
    4WD will not disengage (when shift cam positioned manually in 2H with shifter linkage removed)
    • Transfer case shift components:
      • Lockup fork (item 71).
      • Lockup hub assembly (item 42)
      • Mechanical shift cam (item 20).
      • Detent spring (item 15).
      • Detent roller (item 16).
      • Reduction shift fork assembly (item 72).
    • Oil pump 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 oil pump assembly and INSTALL pump filter. INSPECT slip yokes and bushings for unusual wear.
    Transfer case overfull
    • Input flange seal (item 33).
    		 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 transfer case input seal for damage.
    Rear output leak
    • Yoke to extension housing seal (item 56).
    • Slip yoke damage or degradation.
    • Internal or external contamination.
    		 INSPECT slip yoke for damage or excessive wear. If wear noted to slip 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.
    NVH
    • Loose driveshafts.
    • Loose screws or bolts.
    • Drive chain (item 22).
    • 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 new components as necessary. If signs of heat generation are noted, REPLACE pump assembly and install pump filter. INSPECT driveshaft slip yoke and INSTALL new as required.
    4WD will not disengage (when shift cam positioned manually in 2H with shifter linkage removed)
    • Transfer case shift components:
      • Lockup fork (item 71).
      • Lockup hub assembly (item 42).
      • Mechanical shift cam (item 20).
      • Detent spring (item 15).
      • Detent roller (item 16).
      • Reduction shift fork assembly (item 72).
    • Oil pump 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 oil pump assembly and install pump filter. INSPECT slip yokes and bushings for unusual wear.
    Shift lever buzz
    • Vehicle shift linkage.
    • Transfer case detent roller (item 16) or detent spring (item 15).
    		 INSPECT system for looseness. TIGHTEN shift system components as required. INSTALL new components as required.
    Uncommanded shift
    • Transfer case shift components:
      • Lockup fork (item 71).
      • Lockup hub assembly (item 42).
      • Mechanical shift cam (item 20).
      • Detent spring (item 15).
      • Detent roller (item 16).
      • Reduction shift fork assembly (item 72).
    • Fork pads worn.
    		 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 oil pump assembly and INSTALL pump filter. INSPECT slip yokes and bushings for unusual wear.
    4WD lights flashing or staying on
    • Vehicle shift linkage.
    • Transfer case mode indication switch (item 1).
    		 INSPECT system linkage for looseness. REPAIR as required. REMOVE shift linkage and VERIFY transfer case operation vs. mode indication switch operation. INSPECT position switch for correct connection. INSPECT position switch and vehicle side connector for sign of contamination or corrosion. INSTALL a new position switch as required.
  8. Remove the coil return wire from the electrical connector.
    1. Remove the wire connector spacer.
    2. Remove the coil wire and pin.
      • Use an electrical connector pin extractor tool.
    Fig 5: Identifying Coil Return Wire
    GF0004066Courtesy of FORD MOTOR CO.
  9. Remove the output shaft speed (OSS) sensor.
    Fig 6: Identifying Output Shaft Speed (OSS) Sensor
    GF0004067Courtesy of FORD MOTOR CO.
  10. Remove the extension housing.
    1. Remove the 6 extension housing bolts.
    2. Remove the extension housing.
    Fig 7: Identifying Extension Housing
    GF0004068Courtesy of FORD MOTOR CO.
  11. Remove the speed sensor tone wheel.
    1. Remove the tone wheel spacer clip.
    2. Pull off the speed sensor tone wheel and discard.
    Fig 8: Removing Speed Sensor Tone Wheel
    GF0004069Courtesy of FORD MOTOR CO.
  12. Remove the rear output shaft snap ring.
    • Lift up on the output shaft while removing the snap ring.
    Fig 9: Removing Rear Output Shaft Snap Ring
    GF0004070Courtesy of FORD MOTOR CO.
    13. NOTE: The bolts are self-tapping, and it is normal to find metal shavings while removing the cover.
    Fig 10: Removing Transfer Case Bolts
    GF0004071Courtesy of FORD MOTOR CO.
  13. Remove the bolts.
    14. NOTE: Use pry bosses to separate the cover from the case.
    Fig 11: Separating Transfer Case Covers
    GF0004072Courtesy of FORD MOTOR CO.
  14. Separate the transfer case covers.
  15. Remove the coil.
    1. Remove the 3 coil-to-cover nuts.
    2. Remove the coil.
    Fig 12: Removing Coil
    GF0004073Courtesy of FORD MOTOR CO.
  16. Using the special tools, remove the rear output shaft bearing.
    Fig 13: Removing Rear Output Shaft Bearing
    GF0004074Courtesy of FORD MOTOR CO.
  17. Using the special tools, remove the front output shaft bearing.
    Fig 14: Removing Front Output Shaft Bearing
    GF0004075Courtesy of FORD MOTOR CO.
  18. Remove the shift collar hub snap ring.
    Fig 15: Removing Shift Collar Hub Snap Ring
    GF0004076Courtesy of FORD MOTOR CO.
  19. Remove the coil housing.
    Fig 16: Removing Coil Housing
    GF0004077Courtesy of FORD MOTOR CO.
  20. Remove the shift fork.
    1. Remove the lockup hub.
    2. Remove the shift fork and spring.
    Fig 17: Removing Shift Fork
    GF0004078Courtesy of FORD MOTOR CO.
    21. NOTE: Remove the lockup hub assembly as a single unit. If disassembly is required, proceed with the following.
    Fig 18: Disassembling Lockup Hub Assembly
    GF0004079Courtesy of FORD MOTOR CO.
  21. 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.
  22. Remove the spacer.
    Fig 19: Removing Spacer
    GF0004080Courtesy of FORD MOTOR CO.
  23. Remove the drive chain and sprockets as an assembly.
    Fig 20: Removing Drive Chain And Sprockets
    GF0004081Courtesy of FORD MOTOR CO.
  24. Remove the magnet from its slot in the case.
    Fig 21: Identifying Magnet
    GF0004082Courtesy of FORD MOTOR CO.
    25. NOTE: The pump assembly is not repairable.
    Fig 22: Removing Oil Pump And Output Shaft
    GF0004083Courtesy of FORD MOTOR CO.
  25. Remove the oil pump and the output shaft as an assembly.
    • Remove the oil pump from the output shaft.
  26. Remove the shift rail.
    Fig 23: Removing Shift Rail
    GF0004084Courtesy of FORD MOTOR CO.
  27. Remove the shift fork and the reduction hub.
    1. Remove the shift fork.
    2. Remove the reduction hub.
    Fig 24: Removing Shift Fork And Reduction Hub
    GF0004085Courtesy of FORD MOTOR CO.
  28. Using the special tool, remove the input seal.
    Fig 25: Removing Input Seal Using Special Tool
    GF0004086Courtesy of FORD MOTOR CO.
    29. CAUTION: Do not let the front planet carrier fall while removing the snap ring.
    Fig 26: Removing Front Planet Carrier
    GF0004087Courtesy of FORD MOTOR CO.
  29. Remove the front planet carrier.
    1. Remove the front planet carrier snap ring.
    2. Remove the front planet carrier.
  30. If necessary, using the special tools, remove the bushing from the front planet.
    Fig 27: Removing Bushing From Front Planet Using Special Tools
    GF0004088Courtesy of FORD MOTOR CO.
  31. Using a drift and a hammer, remove the needle bearing, if necessary.
    Fig 28: Removing Needle Bearing
    GF0004089Courtesy of FORD MOTOR CO.
  32. Remove the ring gear.
    1. Remove the ring gear snap ring.
    2. Remove the ring gear.
      Fig 29: Removing Ring Gear
      GF0004090Courtesy of FORD MOTOR CO.
  33. Remove the front planet carrier bearing snap ring. Then, using the special tools, remove the front planet carrier bearing.
    Fig 30: Removing Front Planet Carrier Bearing Snap Ring
    GF0004091Courtesy of FORD MOTOR CO.
    34. CAUTION: Do not let the front output shaft fall while removing the snap ring.
    Fig 31: Removing Front Output Shaft
    GF0004092Courtesy of FORD MOTOR CO.
  34. Remove the front output shaft.
    1. Remove the front output shaft snap ring.
    2. Remove the front output shaft.
  35. Using the special tools, remove the front output shaft bearing.
    Fig 32: Removing Front Output Shaft Bearing
    GF0004093Courtesy of FORD MOTOR CO.
  36. Using the special tools, remove the front yoke to flange seal.
    Fig 33: Removing Front Yoke To Flange Seal
    GF0004094Courtesy of FORD MOTOR CO.
    37. NOTE: Access the shift lever set screw through the mode indicator switch hole.
    Fig 34: Locating Shift Lever Set Screw
    GF0004095Courtesy of FORD MOTOR CO.
  37. Loosen the shift lever set screw.
  38. Remove the shift lever (from outside of case), shift cam detent spring and detent roller.
    Fig 35: Removing Shift Lever
    GF0004096Courtesy of FORD MOTOR CO.
  39. Using the special tools, remove the shift lever seal.
    Fig 36: Removing Shift Lever Seal
    GF0004097Courtesy of FORD MOTOR CO.
  40. Remove the dust shield, if necessary.
    Fig 37: Removing Dust Shield
    GF0004098Courtesy of FORD MOTOR CO.
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