Transfer Case Exploded View - Electronic Shift: Disassembly

WARNING: This page is about a different car, the 2012 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Discard all seals after removing them.

Clean the transfer case with solvent and dry with compressed air.
Using the Transmission Holding Fixture, secure the transfer case to the bench.

Fig 1: Identifying Transmission Holding Fixture
Courtesy of FORD MOTOR CO.
Remove the rear output shaft seal.

Fig 2: Locating Rear Output Shaft Seal
Courtesy of FORD MOTOR CO.
Remove the inner connector retainer. Press the release tab and remove the coil wire from the electric shift motor electrical connector.

Fig 3: Locating Coil Wire Pin In Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the 3 transfer case shift motor bolts, bracket bolt and loosen the 2 bracket nuts.

Fig 4: Locating Transfer Case Shift Motor Bolts
Courtesy of FORD MOTOR CO.

NOTE: The transfer case bolts are self tapping, and it is normal to find metal shavings while removing the cover.

Fig 5: Locating Transfer Case Bolts

G06128056

Courtesy of FORD MOTOR CO.

Remove the 20 transfer case bolts.
Using the pry bosses, separate the transfer case covers.

Fig 6: Locating Transfer Case Covers
Courtesy of FORD MOTOR CO.
Remove the 3 transfer case field coil nuts, washers and transfer case field coil.

Fig 7: Locating Transfer Case Field Coil Nuts And Washers
Courtesy of FORD MOTOR CO.
Using the Bearing Cup Remover with the Slide Hammer, remove the rear output shaft bearing.

Fig 8: Removing Rear Output Shaft Support Bearing
Courtesy of FORD MOTOR CO.
Using the Bearing Cup Remover with the Slide Hammer, remove the front output shaft bearing.

Fig 9: Removing Front Output Shaft Bearing
Courtesy of FORD MOTOR CO.
Remove the shift collar hub snap ring.

Fig 10: Locating Shift Collar Hub Snap Ring
Courtesy of FORD MOTOR CO.
Remove the coil housing.

Fig 11: Removing Coil Housing
Courtesy of FORD MOTOR CO.
Remove the shift fork.
1. Remove the lockup hub.
2. Remove the shift fork and spring.
  
  Fig 12: Removing Shift Fork And Spring
  Courtesy of FORD MOTOR CO.

NOTE: Remove the lockup hub assembly as a single unit. If disassembly is required, proceed with the following.

Disassemble the lockup hub assembly.
1. Remove the lockup hub snap ring.
2. Separate the lockup collar.
3. Separate the 2 lockup springs.
4. Separate the lockup hub.
5. Remove the armature.
  
  Fig 13: Disassembling Lockup Hub Assembly
  Courtesy of FORD MOTOR CO.

NOTE: Remove the drive chain and sprockets as an assembly.

Fig 14: Removing Drive Chain And Sprockets

G06171752

Courtesy of FORD MOTOR CO.

Remove the drive chain, sprockets and the thrust washer.
Remove the magnet from its slot in the case.

Fig 15: Removing Magnet From Slot In Case
Courtesy of FORD MOTOR CO.

NOTE: The pump assembly is not repairable.

Fig 16: Removing Oil Pump And Output Shaft

G06171824

Courtesy of FORD MOTOR CO.

Remove the oil pump and the output shaft as an assembly. Remove the oil pump from the output shaft.
Remove the shift rail.

Fig 17: Locating Shift Fork Shaft
Courtesy of FORD MOTOR CO.
Remove the shift fork and the reduction hub.
1. Remove the shift fork.
2. Remove the reduction hub.
  
  Fig 18: Removing Shift Fork And Reduction Hub
  Courtesy of FORD MOTOR CO.

NOTE: The electric shift cam is serviced as an assembly. Do not disassemble the shift cam assembly.

Fig 19: Removing Electric Shift Cam Assembly

G06171827

Courtesy of FORD MOTOR CO.

Remove the electric shift cam assembly.
Remove the front planet carrier.

Fig 20: Locating Front Planet Carrier
Courtesy of FORD MOTOR CO.
Remove and discard the front input shaft seal.

Fig 21: Locating Front Input Shaft Seal
Courtesy of FORD MOTOR CO.
Remove the thrust bearing.
- Remove the needle bearing, if necessary.
  
  Fig 22: Locating Thrust Bearing
  Courtesy of FORD MOTOR CO.
Remove the ring gear.
1. Remove the ring gear snap ring.
2. Remove the ring gear.
  
  Fig 23: Identifying Ring Gear And Snap Ring
  Courtesy of FORD MOTOR CO.
Using the Stator Bearing Remover with the Slide Hammer, remove the front planet carrier bearing.

Fig 24: Removing Front Planet Carrier Bearing Using Special Tool
Courtesy of FORD MOTOR CO.
Remove the driven sprocket spacer.

Fig 25: Locating Driven Sprocket Spacer
Courtesy of FORD MOTOR CO.

NOTE: Do not let the front output shaft fall while removing the snap ring or damage to the component may occur.

Remove the front output shaft.
1. Remove the front output shaft snap ring.
2. Remove the front output shaft.
  
  Fig 26: Removing Front Output Shaft
  Courtesy of FORD MOTOR CO.
Using the Stator Bearing Remover with the Slide Hammer, remove the front output shaft bearing.

Fig 27: Removing Front Output Shaft Bearing Using Special Tool
Courtesy of FORD MOTOR CO.
Using the Bearing Cup Remover with the Slide Hammer, remove the front output shaft seal.

Fig 28: Removing Front Output Shaft Seal Using Special Tool
Courtesy of FORD MOTOR CO.