Transfer Case Front Output Shaft Seal - Vehicles With: 2-Speed Torque On Demand Transfer Case: Removal

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.

Remove the transfer case. Refer to: Transfer Case .
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.

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

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Remove the transfer case rear seal. Refer to: Transfer Case Rear Seal .
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.
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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.
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Clean the transfer case shift motor mating surfaces. Refer to: RTV Sealing Surface Cleaning and Preparation .

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Remove the coil nuts and washers.

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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.

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Using the pry bosses, separate the transfer case covers.

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Remove the transfer case field coil.

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Remove the coil housing snap ring.

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Remove the caged thrust bearing assembly.
- Install a new bearing as necessary.
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Remove the coil housing.

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Remove the steel balls and the cam.

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Remove the wave spring.

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Remove clutch pack circlip.

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NOTE: When removing the clutch pack assembly, do not separate the clutch pack assembly. Keep tension on the clutch pack during removal. Set the clutch pack assembly on the bench in the same position as located in the transfer case. The thrust washer in the lower clutch pack uses tabs to hold it in place. If the thrust washer is not in place, a transfer case clearance problem will occur.

NOTE: If the clutch pack is disassembled, a new clutch pack and armature must be installed. Failure to install a new clutch pack can result in component failure.

Remove the clutch pack assembly with the armature.

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Remove the drive chain and the sprockets as an assembly.
- Install new components as necessary.
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Remove the output shaft sprocket spacer.

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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 output shaft.

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Remove and discard the front output shaft seal.

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