Mechanical 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 3-position switch.
   Fig 2: Removing 3-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 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. Remove and discard the 8 rear retainer bolts.
    Fig 10: Locating Rear Retainer Bolts

    Courtesy of FORD MOTOR CO.

    All vehicles 

11. Separate the rear retainer from the rear case and remove the rear retainer.
    Fig 11: Separating 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 Front Pump Bushing Remover With Handle And Suitable Press

    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: Separating Case Halves

    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 Drive Pinion Bearing Cup Installer With Handle And Suitable Press

    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 Sprockets And Chain As An Assembly

    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: Identifying Mode Fork, Shift Rail And Mode 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: Locating Clutch Gear

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

    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: Inspecting 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: Positioning Range Fork Assembly And Range Shift Sleeve In Front Case
Courtesy of FORD MOTOR CO.
34. Remove the range fork assembly and the range shift sleeve.
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: Inspecting Range Fork Pads For Wear

    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 With 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 Input Bearing Retaining 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 Drive Pinion Bearing Cup Installer And A Suitable Press

    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 Torque Converter Fluid Seal Remover With Slide Hammer

    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 Rear Axle Oil Seal Installer With Handle And Suitable Press

    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: Lifting Out 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: Inspecting Gear Teeth And Thrust Washers For Wear And Damage

    Courtesy of FORD MOTOR CO.
52. Remove the poppet assembly.
    Fig 49: 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 50: Locating Poppet Screw, Spring And Poppet
Courtesy of FORD MOTOR CO.
53. Disassemble the poppet screw, the spring and the poppet.
54. Remove the locknut, the washer and the sector assembly.
    Fig 51: Locating Locknut, Washer And Sector Assembly

    Courtesy of FORD MOTOR CO.