Transfer Case - Mechanical 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: Identifying Transfer Case
Courtesy of FORD MOTOR CO.
Remove the 3 position switch.

Fig 2: Locating Position Switch
Courtesy of FORD MOTOR CO.

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

Fig 3: Locating Drain And Fill Plugs

G04650882

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: Turning 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: Turning 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: Locating 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: 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: 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: Identifying 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, then remove the rear case.

Fig 16: Removing Rear Case
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: 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: 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 sprockets and chain as an assembly.

Fig 25: Removing Sprockets And Chain Assembly
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 sleeve off the mainshaft and separate the components.

Fig 27: Locating Mode 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 mode hub.
Remove the drive sprocket hub.

Fig 29: 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 30: Locating Mode Fork Pads For Wear
Courtesy of FORD MOTOR CO.

NOTE: Rotate the sector assembly to the 4-wheel high position for easy removal.

Fig 31: Locating Range Shift Sleeve

G04650910

Courtesy of FORD MOTOR CO.

Remove the range fork assembly and the range shift sleeve.
Inspect the range fork pads for wear. If the pads are worn, discard the range fork, the pads, the mainshaft and the sleeve.

Fig 32: Locating Pads Mainshaft And Sleeve
Courtesy of FORD MOTOR CO.
Using the special tools, remove the input seal.

Fig 33: Using Special Tools In 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 34: Identifying Retaining Ring
    Courtesy of FORD MOTOR CO.
Remove the planetary assembly.

Fig 35: Locating Planetary Assembly
Courtesy of FORD MOTOR CO.
Remove the input bearing retaining ring.

Fig 36: Locating Input Bearing Retaining Ring
Courtesy of FORD MOTOR CO.
Using the special tool and a suitable press, remove the front input bearing.

Fig 37: Locating Front Input Bearing
Courtesy of FORD MOTOR CO.
Using the special tools, remove the front output seal.

Fig 38: 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 39: Using Special Tool On Retaining Ring
  Courtesy of FORD MOTOR CO.
Remove the special tool and the front output shaft.

Fig 40: Using Special Tool On Front Output Shaft
Courtesy of FORD MOTOR CO.
Remove the front output ball bearing retaining ring.

Fig 41: 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 42: Using Special Tool On Front Output Ball Bearing
Courtesy of FORD MOTOR CO.
Remove the lock plate retaining ring.

Fig 43: 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 44: Locating Input Gear
  Courtesy of FORD MOTOR CO.
Remove the lock plate.

Fig 45: Locating Lock Plate
Courtesy of FORD MOTOR CO.
Remove the front input gear thrust washer.

Fig 46: Locating Front Input Gear Thrust Washer
Courtesy of FORD MOTOR CO.
Remove the rear input gear thrust washer.

Fig 47: 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 48: Locating Planetary Gear Assembly
Courtesy of FORD MOTOR CO.
Remove the poppet assembly.

Fig 49: Locating 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 50: Locating Poppet Screw, Spring And Poppet

G04650929

Courtesy of FORD MOTOR CO.

Disassemble the poppet screw, the spring and the poppet.
Remove the locknut, the washer, the lever, the spacer and the sector assembly.

Fig 51: Locating Locknut
Courtesy of FORD MOTOR CO.
Using the special tool, remove the sector shaft support.

Fig 52: Using Special Tool On Sector Shaft Support
Courtesy of FORD MOTOR CO.
Remove and discard the support O-ring seal.

Fig 53: Locating Support O-Ring Seal
Courtesy of FORD MOTOR CO.