Transfer Case - Electronic Shift: Disassembly

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: 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.
Remove the drain and fill plugs.

Fig 3: Identifying Fill Plugs
Courtesy of FORD MOTOR CO.
Using the special tool to prevent the flange from turning, remove and discard the front output nut.

Fig 4: Removing Front Output Nut
Courtesy of FORD MOTOR CO.
Using a suitable 2- or 3-jaw puller, remove the flange.

Fig 5: Removing Flange
Courtesy of FORD MOTOR CO.
Using the special tool to prevent the flange from turning, remove and discard the rear output nut.

Fig 6: Removing Rear Output Nut
Courtesy of FORD MOTOR CO.
Using a suitable 2- or 3-jaw puller, remove the flange.

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

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

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

Fig 10: Identifying 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: Removing Rear Retainer
Courtesy of FORD MOTOR CO.
Using the special tools and a suitable press, remove the needle bearing.

Fig 12: Locating Needle Bearing
Courtesy of FORD MOTOR CO.
Disconnect the oil tube and remove the oil pump assembly.

Fig 13: Removing 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: Identifying Retaining Ring
Courtesy of FORD MOTOR CO.
Remove and discard the 25 case bolts.

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

Fig 16: Removing Rear Case
Courtesy of FORD MOTOR CO.
Remove the oil tube.

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

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

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

Fig 20: Removing Needle Bearing
Courtesy of FORD MOTOR CO.
Remove the chip collector magnet.

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

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

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

Fig 24: Identifying 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, Driven Sprocket And Drive Chain
Courtesy of FORD MOTOR CO.
Remove the mainshaft and the mode fork as an assembly.

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

Fig 27: Identifying Mode Fork And Synchronizer Sleeve
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: Identifying Retaining Ring And Synchronizer Hub
Courtesy of FORD MOTOR CO.
Remove the outer ring.

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

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

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

Fig 33: Identifying 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: 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 35: Identifying Range Fork And Range Shift Sleeve

GF0007556

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: Inspecting Range Fork Pads For Wear

GF0007557

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: Identifying Retaining Ring
Courtesy of FORD MOTOR CO.
Remove the planetary assembly.

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

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

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

Fig 42: Removing 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: Identifying 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: Identifying Front Output Ball Bearing
Courtesy of FORD MOTOR CO.
Remove the lock plate retaining ring.

Fig 47: Identifying 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: Inspecting Input Gear
Courtesy of FORD MOTOR CO.
Remove the lock plate.

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

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

Fig 51: Identifying 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: Inspecting Gear Teeth And Thrust Washers
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: Identifying Poppet Screw, Spring And Poppet

GF0007575

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: Identifying 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: Identifying Support O-Ring Seal
Courtesy of FORD MOTOR CO.