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Transfer Case - Vehicles With: Electronic Shift Transfer Case: Disassembly

WARNING: This page is about a different car, the 2020 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.
  1. NOTE: Seal all openings before cleaning the transfer case exterior. This will prevent entry of dirt and water, which may cause damage to internal components.

    Using a transmission adjustable mounting arm, secure the transfer case to the bench. Clean the transfer case with solvent and dry with compressed air. Use the General Equipment: Adjustable Mounting Arm

    GFD464824Courtesy of FORD MOTOR COMPANY
  2. Remove the transfer case rear seal. Refer to: Transfer Case Rear Seal .
  3. Remove the coil wire pin from the electrical connector.

    1. Remove the inner retainer from the wire connector.
    2. Press the release tab and remove the coil wire pin.

    GFD464825Courtesy of FORD MOTOR COMPANY
    1. Loosen the transfer case shift motor bracket nuts.
    2. Remove the transfer case shift motor bracket bolt.
    3. Remove the transfer case shift motor bolts.
    4. Remove the transfer case shift motor.
    GFD464826Courtesy of FORD MOTOR COMPANY
  5. Remove the coil nuts and washers.
    GFD464828Courtesy of FORD MOTOR COMPANY
  6. 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.

    GFD464829Courtesy of FORD MOTOR COMPANY
  7. NOTE: Use care not damage the field coil wire.

    Using the pry bosses, separate the transfer case covers.

    GFD464830Courtesy of FORD MOTOR COMPANY
  8. Remove the transfer case field coil.
    GFD464854Courtesy of FORD MOTOR COMPANY
  9. Remove the field coil housing snap ring.
    GFD464855Courtesy of FORD MOTOR COMPANY
  10. Remove the field coil housing.
    GFD464856Courtesy of FORD MOTOR COMPANY
  11. Remove the lock up hub, shift fork and shift fork spring.
    GFD464857Courtesy of FORD MOTOR COMPANY
  12. 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.

    GFD464911Courtesy of FORD MOTOR COMPANY
  13. NOTE: Remove the drive chain and sprockets as an assembly.

    Remove the drive chain and sprockets.

    GFD464858Courtesy of FORD MOTOR COMPANY
  14. Remove the sprocket thrust washer.
    GFD464912Courtesy of FORD MOTOR COMPANY
  15. Remove the magnet from its slot in the case.
    GFD464879Courtesy of FORD MOTOR COMPANY
  16. NOTE: The pump assembly is not repairable.

    Remove the oil pump assembly.

    GFD464880Courtesy of FORD MOTOR COMPANY
  17. Remove the shift rail.
    GFD464881Courtesy of FORD MOTOR COMPANY
  18. Remove the shift fork.
    GFD464882Courtesy of FORD MOTOR COMPANY
  19. Remove the output shaft.
    GFD464883Courtesy of FORD MOTOR COMPANY
  20. Remove the reduction hub.
    GFD464884Courtesy of FORD MOTOR COMPANY
  21. NOTE: The electric shift cam is serviced as an assembly. Do not disassemble the shift cam assembly.

    Remove the electric shift cam assembly.

    GFD464885Courtesy of FORD MOTOR COMPANY
  22. Remove the planet carrier thrust bearing.
    GFD464886Courtesy of FORD MOTOR COMPANY
  23. Remove the ring gear circlip.
    GFD464887Courtesy of FORD MOTOR COMPANY
  24. NOTE: Replace the inner planet carrier needle bearing if necessary.

    Remove the front planet carrier.

    GFD464888Courtesy of FORD MOTOR COMPANY
  25. Remove the ring gear.
    GFD464889Courtesy of FORD MOTOR COMPANY
  26. NOTE: Do not let the front output shaft fall while removing the snap ring or damage to the component may occur.

    Remove the output shaft circlip and the out put shaft.

    GFD464841Courtesy of FORD MOTOR COMPANY
  27. Remove and discard the front input shaft seal and the front output shaft seal.
    GFD464890Courtesy of FORD MOTOR COMPANY
  28. 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
    GFD464891Courtesy of FORD MOTOR COMPANY
  29. Using the special tool and a Slide Hammer, remove the front output shaft support bearing. Use Special Service Tool: 307-318 Remover, Stator Bearing. Use the General Equipment: Slide Hammer
    GFD464892Courtesy of FORD MOTOR COMPANY
  30. Using the special tool with the Slide Hammer, remove the front output shaft bearing. Use Special Service Tool: 308-047 (T77F-1102-A) Remover, Bearing Cup. Use the General Equipment: Slide Hammer
    GFD464859Courtesy of FORD MOTOR COMPANY
  31. Using the special tool and a Slide Hammer, remove the front planet carrier bearing. Use Special Service Tool: 308-047 (T77F-1102-A) Remover, Bearing Cup. Use the General Equipment: Slide Hammer
    GFD464893Courtesy of FORD MOTOR COMPANY
  32. Clean and inspect the components of the transfer case for damage and install new components as necessary.
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