Transfer Case - Vehicles With: 2-Speed Torque On Demand Transfer Case: Disassembly

WARNING: This page is about a different car, the 2021 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.

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

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Remove and discard the transfer case rear output shaft seal.

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Remove the bolt and the vibration damper from the transfer case.

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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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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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NOTE: Use care not damage the field coil wire.

Using the pry bosses, separate the transfer case covers.

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Remove the dowel pins.

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Remove the transfer case field coil.

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Remove the coil housing snap ring and spacer.

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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 clutch pack spacer.

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Remove the front output shaft spacer.

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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 thrust bearing assembly.
- NOTE: The upper thrust washer may be attached to the sprocket.
  
  Remove the thrust washer.
- Remove the thrust bearing.
- Remove the thrust washer.
- Install new components as necessary.
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Remove the magnet from its slot in the case.

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NOTE: The pump assembly is not repairable.

Remove the oil pump assembly.

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Remove the shift rail.

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Remove the shift fork.

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Remove the output shaft.

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Remove the reduction hub.

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

Remove the electric shift cam assembly.

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Remove the planet carrier thrust bearing.

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Remove the ring gear circlip.

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NOTE: Replace the inner planet carrier needle bearing if necessary.

Remove the front planet carrier.

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Remove the ring gear.

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Remove the front output shaft seal dust cover.

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Remove the front output shaft.

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Remove and discard the front output shaft seal.

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Remove and discard the input shaft seal.

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Using the special tool with the Slide Hammer, remove the planet carrier bearing.
Use Special Service Tool: 308-047 (T77F-1102-A) Remover, Bearing Cup.

Use the General Equipment: Slide Hammer

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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

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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

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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

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Remove and discard the shift shaft seal.

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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.