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Transfer Case: Disassembly

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  1. Using a transmission adjustable mounting arm, secure the transfer case to the bench.. Use the General Equipment: Adjustable Mounting Arm
    GFD626623Courtesy of FORD MOTOR COMPANY
  2. Using the special tool, remove and discard the pinion flange nut. Use Special Service Tool: 205-126 (T78P-4851-A) Holding Fixture, Drive Pinion Flange.
    GFD626610Courtesy of FORD MOTOR COMPANY
  3. Index mark the rear output flange and the rear output shaft for reassembly.
    GFD626954Courtesy of FORD MOTOR COMPANY
  4. Remove the output flange.. Use the General Equipment: Puller
    GFD626612Courtesy of FORD MOTOR COMPANY
  5. Remove and discard the rear output shaft seal.
    GFD626613Courtesy of FORD MOTOR COMPANY
  6. Using the special tool, remove and discard the pinion flange nut. Use Special Service Tool: 205-126 (T78P-4851-A) Holding Fixture, Drive Pinion Flange.
    GFD626955Courtesy of FORD MOTOR COMPANY
  7. Index mark the front output flange and the front output shaft for reassembly.
    GFD626597Courtesy of FORD MOTOR COMPANY
  8. Remove the front output flange.. Use the General Equipment: Puller
    GFD626598Courtesy of FORD MOTOR COMPANY
  9. Remove and discard the front output shaft seal.
    GFD626599Courtesy of FORD MOTOR COMPANY
  10. Remove the mounting bolts and the transfer case shift motor.
    GFD626626Courtesy of FORD MOTOR COMPANY
  11. Remove and discard the transfer case shift motor O-ring seal.
    GFD626576Courtesy of FORD MOTOR COMPANY
  12. Remove the input shaft seal. Use Special Service Tool: 308-375 Remover, Input Shaft Seal.. Use the General Equipment: Slide Hammer
    GFD626605Courtesy of FORD MOTOR COMPANY
  13. NOTE: The transfer case bolts are self tapping, and it is normal to find metal shavings while removing the cover.

    Remove the transfer case bolts.

    GFD626627Courtesy of FORD MOTOR COMPANY
  14. NOTE: Use care not damage the field coil wire.

    Using the pry bosses, separate the transfer case covers.

    GFD626628Courtesy of FORD MOTOR COMPANY
  15. Remove the dowel pins.
    GFD626629Courtesy of FORD MOTOR COMPANY
  16. Remove and discard the rear output shaft bearing circlip.
    GFD626630Courtesy of FORD MOTOR COMPANY
  17. Using the special tool with the Slide Hammer, remove the rear output shaft bearing. Use Special Service Tool: 308-047 (T77F-1102-A) Remover, Bearing Cup.. Use the General Equipment: Slide Hammer
    GFD626631Courtesy of FORD MOTOR COMPANY
  18. NOTE: The pump assembly is not repairable.

    Remove the oil pump assembly.

    GFD626632Courtesy of FORD MOTOR COMPANY
  19. Remove and discard the output shaft lock hub circlip and remove the output shaft lock hub.
    GFD626633Courtesy of FORD MOTOR COMPANY
  20. Remove the transfer case synchronizer.
    GFD626634Courtesy of FORD MOTOR COMPANY
  21. Remove and discard the transfer case synchronizer criclip.
    GFD626635Courtesy of FORD MOTOR COMPANY
  22. Remove the transfer case synchronizer strut.
    GFD626636Courtesy of FORD MOTOR COMPANY
  23. Remove and discard the shift fork snap ring and remove the shift fork.
    GFD626637Courtesy of FORD MOTOR COMPANY
  24. NOTE: Remove the disengage pin from the control shift rod groove.

    Remove the shift rod.

    GFD626638Courtesy of FORD MOTOR COMPANY
  25. NOTE: Remove the drive chain and sprockets as an assembly.

    Remove the drive chain and sprockets.

    GFD626639Courtesy of FORD MOTOR COMPANY
  26. Remove and discard the front output shaft bearing.. Use the General Equipment: Bearing Separator. Use the General Equipment: Hydraulic Press
    GFD626640Courtesy of FORD MOTOR COMPANY
  27. Remove and discard the front output shaft bearing.. Use the General Equipment: Bearing Separator. Use the General Equipment: Hydraulic Press
    GFD626641Courtesy of FORD MOTOR COMPANY
  28. Remove the output shaft.
    GFD626642Courtesy of FORD MOTOR COMPANY
  29. NOTE: Rotate the control shift rod until the H-L shift rod assembly pin is aligned with the longitudinal groove of the control shift rod.

    Remove the electric shift cam assembly.

    GFD626643Courtesy of FORD MOTOR COMPANY
  30. Remove the shift fork.
    GFD626644Courtesy of FORD MOTOR COMPANY
  31. Remove and discard the shift fork snap ring.
    GFD626645Courtesy of FORD MOTOR COMPANY
  32. NOTE: Make sure that the component is not damaged.

    Remove and discard the input shaft circlip

    GFD626646Courtesy of FORD MOTOR COMPANY
  33. Remove the planet carrier.
    GFD626647Courtesy of FORD MOTOR COMPANY
  34. Remove and discard the planet carrier circlip.
    GFD626648Courtesy of FORD MOTOR COMPANY
  35. Remove the planet carrier input shaft.
    GFD626649Courtesy of FORD MOTOR COMPANY
  36. Remove and discard planet carrier input shaft bearing circlip and remove the planet carrier input shaft bearing.
    GFD626650Courtesy of FORD MOTOR COMPANY
  37. Remove and discard the ring gear circlip and remove the ring gear.
    GFD626651Courtesy of FORD MOTOR COMPANY
  38. Remove and discard the input shaft bearing circlip.
    GFD626652Courtesy of FORD MOTOR COMPANY
  39. Remove the input shaft bearing Use Special Service Tool: 308-047 (T77F-1102-A) Remover, Bearing Cup.. Use the General Equipment: Slide Hammer
    GFD626653Courtesy of FORD MOTOR COMPANY
  40. Remove the plate.
    GFD626654Courtesy of FORD MOTOR COMPANY
  41. NOTE: Clean and inspect the components of the transfer case for damage and install new components as necessary.

    Clean the transfer case with solvent and dry with compressed air.

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