Transfer Case - Mechanical Shift: Disassembly

All vehicles 

1. Attach the transfer case to the Transmission Holding Fixture.
   Fig 1: Removing Transfer Case From Transmission Holding Fixture

   Courtesy of FORD MOTOR CO.
2. Remove the 3-position switch.
   Fig 2: Removing Position Switch

   Courtesy of FORD MOTOR CO.
3. Remove the drain and fill plugs.
   Fig 3: Locating Drain And Fill Plugs

   Courtesy of FORD MOTOR CO.
4. Using the Drive Pinion Flange Holding Fixture to prevent the flange from turning, remove and discard the front output nut.
   Fig 4: Removing Front Driveshaft Flange Nut

   Courtesy of FORD MOTOR CO.
5. Using the 2 or 3 Jaw Puller, remove the flange.
   Fig 5: Removing Flange Using Jaw Pullers

   Courtesy of FORD MOTOR CO.

   Vehicles equipped with a flange 

6. Using the Drive Pinion Flange Holding Fixture to prevent the flange from turning, remove and discard the rear output nut.
   Fig 6: Removing Rear Output Flange Nut Using Drive Pinion Flange Holding Fixture

   Courtesy of FORD MOTOR CO.
7. Using the 2 or 3 Jaw Puller, remove the flange.
   Fig 7: Removing Flange Using Jaw Pullers

   Courtesy of FORD MOTOR CO.
8. Remove the slinger from the front flange and the rear flange, if necessary.
   Fig 8: Locating Front And Rear Flange Slinger

   Courtesy of FORD MOTOR CO.
9. Using the Slide Hammer with the Torque Converter Fluid Seal Remover, remove the rear output seal.
   Fig 9: Removing Rear Output Seal Using Slide Hammer And Torque Converter Fluid Seal Remover

   Courtesy of FORD MOTOR CO.

   Vehicles equipped with a slip yoke 

10. Remove and discard the 8 rear retainer bolts.
    Fig 10: Locating Rear Retainer Bolt

    Courtesy of FORD MOTOR CO.

    All vehicles 

11. Separate the rear retainer from the rear case and remove the rear retainer.
    Fig 11: Removing Rear Retainer From Rear Case

    Courtesy of FORD MOTOR CO.
12. Using the Front Pump Bushing Remover with the Handle and a suitable press, remove the needle bearing.
    Fig 12: Removing Needle Bearing Using Tools

    Courtesy of FORD MOTOR CO.
13. Disconnect the oil tube and remove the oil pump assembly.
    Fig 13: Locating Oil Tube And Oil Pump Assembly

    Courtesy of FORD MOTOR CO.
14. Remove and discard the retaining ring.
    1. Install the Output Shaft Rear Snap Ring Sleeve.
    2. Lift up on the shaft, and remove and discard the retaining ring.
       Fig 14: Removing Retaining Ring

       Courtesy of FORD MOTOR CO.
15. Remove and discard the 25 case bolts.
    Fig 15: Locating Case Bolts

    Courtesy of FORD MOTOR CO.
16. Separate the case halves, then remove the rear case.
    Fig 16: Removing Rear Case

    Courtesy of FORD MOTOR CO.
17. Remove the oil tube.
    Fig 17: Locating Oil Tube

    Courtesy of FORD MOTOR CO.
18. Remove the ball bearing retaining ring.
    Fig 18: Locating Ball Bearing Retaining Ring

    Courtesy of FORD MOTOR CO.
19. Using the Drive Pinion Bearing Cup Installer with the Handle and a suitable press, remove the ball bearing.
    Fig 19: Removing Ball Bearing Using Tools

    Courtesy of FORD MOTOR CO.
20. Using the Universal Puller Set, remove the needle bearing.
    Fig 20: Removing Needle Bearing Using Universal Puller Set

    Courtesy of FORD MOTOR CO.
21. Remove the chip collector magnet.
    Fig 21: Locating Chip Collector Magnet

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

    Courtesy of FORD MOTOR CO.
23. Remove the drive sprocket retaining ring.
    Fig 23: Locating Drive Sprocket Retaining Ring

    Courtesy of FORD MOTOR CO.
24. Remove the mode spring.
    Fig 24: Locating Mode Spring

    Courtesy of FORD MOTOR CO.
25. Remove the sprockets and chain as an assembly.
    Fig 25: Removing Drive Sprockets And Chain

    Courtesy of FORD MOTOR CO.
26. Remove the mainshaft and the mode fork as an assembly.
    Fig 26: Removing Mainshaft And Mode Fork Assembly

    Courtesy of FORD MOTOR CO.
27. Slide the mode sleeve off the mainshaft and separate the components.
    Fig 27: Locating Mode Fork, Shift Rail And Sleeve

    Courtesy of FORD MOTOR CO.
28. Place the mainshaft in a soft-jawed vise with the threaded end upward.
29. Remove the clutch gear.
    Fig 28: Removing Clutch Gear

    Courtesy of FORD MOTOR CO.
30. Remove the mode hub.
31. Remove the drive sprocket hub.
    Fig 29: Locating Mainshaft Drive Sprocket Hub

    Courtesy of FORD MOTOR CO.
32. Inspect all of the components for wear and damage.
33. Inspect the mode fork pads for wear.
    Fig 30: Locating Mode Fork Pads

    Courtesy of FORD MOTOR CO.
34. NOTE: Rotate the sector assembly to the 4-wheel high position for easy removal.

    Remove the range fork assembly and the range shift sleeve.

    Fig 31: Locating Range Fork Assembly And Range Shift Sleeve

    Courtesy of FORD MOTOR CO.
35. 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 Range Fork Pads

    Courtesy of FORD MOTOR CO.
36. Using the Slide Hammer with the Torque Converter Fluid Seal Remover, remove the input seal.
    Fig 33: Removing Input Seal Using Slide Hammer And Torque Converter Fluid Seal Remover

    Courtesy of FORD MOTOR CO.
37. Remove and discard the retaining ring.
    1. Install the Input Shaft Snap Ring Sleeve.
    2. Remove and discard the retaining ring.
       Fig 34: Removing Retaining Ring

       Courtesy of FORD MOTOR CO.
38. Remove the planetary assembly.
    Fig 35: Locating Planetary Assembly

    Courtesy of FORD MOTOR CO.
39. Remove the input bearing retaining ring.
    Fig 36: Locating Bearing Retainer Ring

    Courtesy of FORD MOTOR CO.
40. Using the Drive Pinion Bearing Cup Installer and a suitable press, remove the front input bearing.
    Fig 37: Removing Front Input Bearing Using Tools

    Courtesy of FORD MOTOR CO.
41. Using the Torque Converter Fluid Seal Remover with the Slide Hammer, remove the front input seal.
    Fig 38: Removing Front Input Seal Using Tools

    Courtesy of FORD MOTOR CO.
42. Remove and discard the retaining ring.
    1. Install the Output Shaft Front Snap Ring Sleeve.
    2. Remove and discard the retaining ring.
       Fig 39: Removing Retaining Ring

       Courtesy of FORD MOTOR CO.
43. Remove the Output Shaft Front Snap Ring Sleeve and the front output shaft.
    Fig 40: Removing Output Shaft Front Snap Ring Sleeve And Front Output Shaft

    Courtesy of FORD MOTOR CO.
44. Remove the front output ball bearing retaining ring.
    Fig 41: Locating Front Output Ball Bearing Retaining Ring

    Courtesy of FORD MOTOR CO.
45. Using the Rear Axle Oil Seal Installer with the Handle and a suitable press, remove the front output ball bearing.
    Fig 42: Removing Front Output Ball Bearing Using Tools

    Courtesy of FORD MOTOR CO.
46. Remove the lock plate retaining ring.
    Fig 43: Locating Lock Plate Retaining Ring

    Courtesy of FORD MOTOR CO.
47. 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.
48. Remove the lock plate.
    Fig 45: Locating Lock Plate

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

    Courtesy of FORD MOTOR CO.
50. Remove the rear input gear thrust washer.
    Fig 47: Locating Rear Input Gear Thrust Washer

    Courtesy of FORD MOTOR CO.
51. Inspect the gear teeth and thrust washers for wear and damage. Install a new planetary gear assembly, if necessary.
    Fig 48: Identifying Gear Teeth And Thrust Washers

    Courtesy of FORD MOTOR CO.
52. Remove the poppet assembly.
    Fig 49: Removing Poppet Assembly

    Courtesy of FORD MOTOR CO.
53. NOTE: If installing a new poppet spring, it must be similar in color to the original poppet spring.

    Disassemble the poppet screw, the spring and the poppet.

    Fig 50: Locating Poppet, Spring And Screw

    Courtesy of FORD MOTOR CO.
54. Remove the locknut, the washer and the sector assembly.
    Fig 51: Removing Sector Assembly Locknut

    Courtesy of FORD MOTOR CO.