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Transfer Case - Vehicles With: Electronic Shift 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.
  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

    GFD559893Courtesy of FORD MOTOR COMPANY
  2. Remove and discard the transfer case rear output shaft seal.
    GFD559894Courtesy of FORD MOTOR COMPANY
  3. Remove the bolt and the vibration damper from the transfer case.
    GFD559895Courtesy of FORD MOTOR COMPANY
  4. 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.

    GFD559858Courtesy 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.
    GFD559896Courtesy of FORD MOTOR COMPANY
  6. Remove the coil nuts and washers.
    GFD559897Courtesy of FORD MOTOR COMPANY
  7. 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.

    GFD559898Courtesy of FORD MOTOR COMPANY
  8. NOTE: Use care not damage the field coil wire.

    Using the pry bosses, separate the transfer case covers.

    GFD559899Courtesy of FORD MOTOR COMPANY
  9. Remove the dowel pins.
    GFD559900Courtesy of FORD MOTOR COMPANY
  10. Remove the transfer case field coil.
    GFD559901Courtesy of FORD MOTOR COMPANY
  11. Remove the field coil housing snap ring.
    GFD559902Courtesy of FORD MOTOR COMPANY
  12. Remove the field coil housing.
    GFD559903Courtesy of FORD MOTOR COMPANY
  13. Remove the lock up hub, shift fork and shift fork spring.
    GFD559904Courtesy of FORD MOTOR COMPANY
  14. 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. Remove the armature.
    4. Separate the 2 lockup springs.
    5. Separate the lockup hub.

    GFD559905Courtesy of FORD MOTOR COMPANY
  15. NOTE: Remove the drive chain and sprockets as an assembly.

    Remove the drive chain and sprockets.

    GFD559906Courtesy of FORD MOTOR COMPANY
  16. Remove the sprocket thrust washer.
    GFD559907Courtesy of FORD MOTOR COMPANY
  17. Remove the magnet from its slot in the case.
    GFD559908Courtesy of FORD MOTOR COMPANY
  18. NOTE: The pump assembly is not repairable.

    Remove the oil pump assembly.

    GFD559909Courtesy of FORD MOTOR COMPANY
  19. Remove the shift rail.
    GFD559910Courtesy of FORD MOTOR COMPANY
  20. Remove the shift fork.
    GFD559911Courtesy of FORD MOTOR COMPANY
  21. Remove the output shaft.
    GFD559912Courtesy of FORD MOTOR COMPANY
  22. Remove the reduction hub.
    GFD559913Courtesy of FORD MOTOR COMPANY
  23. NOTE: The electric shift cam is serviced as an assembly. Do not disassemble the shift cam assembly.

    Remove the electric shift cam assembly.

    GFD559914Courtesy of FORD MOTOR COMPANY
  24. Remove the planet carrier thrust bearing.
    GFD559915Courtesy of FORD MOTOR COMPANY
  25. Remove the ring gear circlip.
    GFD559916Courtesy of FORD MOTOR COMPANY
  26. NOTE: Replace the inner planet carrier needle bearing if necessary.

    Remove the front planet carrier.

    GFD559917Courtesy of FORD MOTOR COMPANY
  27. Remove the ring gear.
    GFD559918Courtesy of FORD MOTOR COMPANY
  28. Remove the front output shaft seal dust cover.
    GFD559919Courtesy of FORD MOTOR COMPANY
  29. Remove the front output shaft.
    GFD559920Courtesy of FORD MOTOR COMPANY
  30. Remove and discard the front output shaft seal.
    GFD559921Courtesy of FORD MOTOR COMPANY
  31. Remove and discard the input shaft seal.
    GFD559922Courtesy of FORD MOTOR COMPANY
  32. 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

    GFD559923Courtesy of FORD MOTOR COMPANY
  33. 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

    GFD559924Courtesy of FORD MOTOR COMPANY
  34. 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

    GFD559925Courtesy of FORD MOTOR COMPANY
  35. 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

    GFD559926Courtesy of FORD MOTOR COMPANY
  36. Remove and discard the shift shaft seal.
    GFD559927Courtesy of FORD MOTOR COMPANY
  37. 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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