Electric Shift Transfer Case: Disassembly

All vehicles 

1. Attach the transfer case to the Transmission Holding Fixture.
   Fig 1: Attaching Transfer Case To Transmission Holding Fixture

   Courtesy of FORD MOTOR CO.
2. Remove the gearmotor encoder assembly.
   Fig 2: Removing Gearmotor Encoder Assembly

   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 2 Or 3 Jaw Puller

   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 To Prevent Flange From Turning

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

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

   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 With Torque Converter Fluid Seal Remover

   Courtesy of FORD MOTOR CO.

   Vehicles equipped with a slip yoke 

10. Using a suitable tool, remove the rear output seal.

    All vehicles 

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

    Courtesy of FORD MOTOR CO.
12. Using the Transfer Case Housing Spreader, separate the rear retainer from the rear case and remove the rear retainer.
    Fig 11: Removing Rear Retainer Using Transfer Case Housing Spreader

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

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

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

    Courtesy of FORD MOTOR CO.
17. Using the Transfer Case Housing Spreader separate the case halves and remove the rear case.
    Fig 16: Removing Rear Case Using Transfer Case Housing Spreader Separate Case Halves

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

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

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

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

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

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

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

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

    Courtesy of FORD MOTOR CO.
26. Remove the drive sprocket, driven sprocket and the drive chain as an assembly.
    Fig 25: Removing Sprockets And Chain As An Assembly

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

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

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

    Courtesy of FORD MOTOR CO.
31. Remove the retaining ring and the synchronizer hub.
    Fig 29: Removing Retaining Ring And Synchronizer Hub

    Courtesy of FORD MOTOR CO.
32. Remove the outer ring.
    Fig 30: Locating Outer Ring On Middle Ring

    Courtesy of FORD MOTOR CO.
33. Remove the middle ring.
    Fig 31: Locating Middle Ring On Inner Ring

    Courtesy of FORD MOTOR CO.
34. Remove the inner ring.
    Fig 32: Locating Inner Ring On Drive Sprocket

    Courtesy of FORD MOTOR CO.
35. Remove the drive sprocket hub.
    Fig 33: Locating Drive Sprocket Hub On Mainshaft

    Courtesy of FORD MOTOR CO.
36. Inspect all of the components for wear and damage.
37. Inspect the mode fork pads for wear.
    Fig 34: Inspecting Mode Fork Pads For Wear

    Courtesy of FORD MOTOR CO.
NOTE: Manual shift range fork shown in the illustration, electric shift range fork similar.
NOTE: Rotate the sector assembly to the 4-wheel high position for easy removal.
Fig 35: Positioning Range Fork Assembly And Range Shift Sleeve In Front Case
Courtesy of FORD MOTOR CO.
38. Remove the range fork assembly and the range shift sleeve.
NOTE: Manual shift range fork shown in the illustration, electric shift range fork similar.
Fig 36: Inspecting Range Fork Pads For Wear
Courtesy of FORD MOTOR CO.
39. Inspect the range fork pads for wear. If the pads are worn, discard the range fork, the pads, the mainshaft and the sleeve.
40. Using the Torque Converter Fluid Seal Remover with the Slide Hammer, remove the input seal.
    Fig 37: Removing Input Seal Using Slide Hammer With Torque Converter Fluid Seal Remover

    Courtesy of FORD MOTOR CO.
41. Remove and discard the retaining ring.
    1. Install the Input Shaft Snap Ring Sleeve.
    2. Remove and discard the retaining ring.
       Fig 38: Removing Retaining Ring

       Courtesy of FORD MOTOR CO.
42. Remove the planetary assembly.
    Fig 39: Locating Planetary Assembly

    Courtesy of FORD MOTOR CO.
43. Remove the input bearing retaining ring.
    Fig 40: Locating Input Bearing Retaining Ring

    Courtesy of FORD MOTOR CO.
44. Using the Drive Pinion Bearing Cup Installer and a suitable press, remove the front input bearing.
    Fig 41: Removing Front Input Bearing Using Drive Pinion Bearing Cup Installer And A Suitable Press

    Courtesy of FORD MOTOR CO.
45. Using the Torque Converter Fluid Seal Remover with the Slide Hammer, remove the front output seal.
    Fig 42: Removing Front Input Seal Using Torque Converter Fluid Seal Remover With Slide Hammer

    Courtesy of FORD MOTOR CO.
46. Remove and discard the retaining ring.
    1. Install the Output Shaft Front Snap Ring Sleeve.
    2. Remove and discard the retaining ring.
       Fig 43: Removing Retaining Ring

       Courtesy of FORD MOTOR CO.
47. Remove the Output Shaft Front Snap Ring Sleeve and the front output shaft.
    Fig 44: Removing Output Shaft Front Snap Ring Sleeve And Front Output Shaft

    Courtesy of FORD MOTOR CO.
48. Remove the front output ball bearing retaining ring.
    Fig 45: Locating Front Output Ball Bearing Retaining Ring

    Courtesy of FORD MOTOR CO.
49. Using the Rear Axle Oil Seal Installer with the Handle and a suitable press, remove the front output ball bearing.
    Fig 46: Removing Front Output Ball Bearing Using Rear Axle Oil Seal Installer With Handle And Suitable Press

    Courtesy of FORD MOTOR CO.
50. Remove the lock plate retaining ring.
    Fig 47: Locating Lock Plate Retaining Ring

    Courtesy of FORD MOTOR CO.
51. Lift out the input gear.
    • Inspect the input gear for wear or damage. Install a new gear if necessary.
      Fig 48: Lifting Out Input Gear

      Courtesy of FORD MOTOR CO.
52. Remove the lock plate.
    Fig 49: Locating Lock Plate

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

    Courtesy of FORD MOTOR CO.
54. Remove the rear input gear thrust washer.
    Fig 51: Locating Rear Input Gear Thrust Washer

    Courtesy of FORD MOTOR CO.
55. 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 For Wear And Damage

    Courtesy of FORD MOTOR CO.
56. Remove the poppet assembly.
    Fig 53: Removing Poppet Assembly

    Courtesy of FORD MOTOR CO.
NOTE: If installing a new poppet spring, it must be similar in color to the original poppet spring.
Fig 54: Locating Poppet Screw, Spring And Poppet
Courtesy of FORD MOTOR CO.
57. Disassemble the poppet screw, the spring and the poppet.
58. Remove the plastic retainer and the O-ring, and remove the sector assembly.
    Fig 55: Locating Sector Assembly

    Courtesy of FORD MOTOR CO.