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Transfer Case - AWD: Disassembly

CAUTION: Discard all seals after removing them.

Remove the transfer case from the vehicle. For additional information, refer to TRANSFER CASE .

WARNING: Make sure the holding fixture lock pin is secure.

Fig 1: Securing Transfer Case To A Bench

G03265484

Courtesy of FORD MOTOR CO.

Using the special tool, secure the transfer case to a bench.
Remove the 4 damper bolts, then remove the damper.
If not previously done, remove the drain plug and drain the fluid.
- Install the drain plug when finished draining and tighten to 17 Nm (13 lb-ft).
Fig 2: Installing Drain Plug
Courtesy of FORD MOTOR CO.
Index-mark the output flange and the upper output shaft.

Fig 3: Marking Output Flange And Upper Output Shaft
Courtesy of FORD MOTOR CO.
Using the special tool to hold the output flange, remove the nut.

Fig 4: Removing Nut
Courtesy of FORD MOTOR CO.
Remove the output shaft yoke washer.
Remove the output flange.
Remove and discard the output flange oil seal.
Remove the 17 transfer case cover bolts.
Separate the transfer case halves at the transfer case pry bosses.

Fig 5: Separating Transfer Case Halves At Transfer Case Pry Bosses
Courtesy of FORD MOTOR CO.
Expand the snap ring, then remove the upper output shaft and ring gear.

Fig 6: Removing Upper Output Shaft And Ring Gear
Courtesy of FORD MOTOR CO.
Using the special tool, remove the upper output shaft support bearing.

Fig 7: Removing Upper Output Shaft Support Bearing
Courtesy of FORD MOTOR CO.
Using the special tools, remove and discard the yoke-to-flange seal.

Fig 8: Removing And Discard Yoke-To-Flange Seal
Courtesy of FORD MOTOR CO.
Remove the snap ring, then separate the upper output shaft from the ring gear.

Fig 9: Separating Upper Output Shaft From Ring Gear
Courtesy of FORD MOTOR CO.
Using a screwdriver, carefully remove the oil scoop.

Fig 10: Removing Oil Scoop
Courtesy of FORD MOTOR CO.
Remove the snap ring retaining the bearing on the upper output shaft.

Fig 11: Removing Snap Ring Retaining Bearing On Upper Output Shaft
Courtesy of FORD MOTOR CO.
Using the special tools, remove the bearing.

Fig 12: Removing Bearing
Courtesy of FORD MOTOR CO.
Remove the 4 Torx® head screws, then remove the 2 damper snubbers.

Fig 13: Removing Damper Snubbers
Courtesy of FORD MOTOR CO.
Remove the output shaft thrust washer.

Fig 14: Removing Output Shaft Thrust Washer
Courtesy of FORD MOTOR CO.
Remove the front planetary gear assembly.

Fig 15: Removing Front Planetary Gear Assembly
Courtesy of FORD MOTOR CO.
Remove the thrust washer.

Fig 16: Removing Thrust Washer
Courtesy of FORD MOTOR CO.
Remove the overdrive sun gear, the upper drive sprocket, the drive chain and the lower drive sprocket as an assembly.

Fig 17: Removing Overdrive Sun Gear, Upper Drive Sprocket, Drive Chain And Lower Drive Sprocket As An Assembly
Courtesy of FORD MOTOR CO.
Remove the thrust washer.

Fig 18: Removing Thrust Washer
Courtesy of FORD MOTOR CO.
Remove the clutch assembly.

Fig 19: Removing Clutch Assembly
Courtesy of FORD MOTOR CO.
Remove the input shaft.

Fig 20: Removing Input Shaft
Courtesy of FORD MOTOR CO.
Using the special tools, remove the input shaft bearing.

Fig 21: Removing Input Shaft Bearing
Courtesy of FORD MOTOR CO.
While holding the front output shaft, remove the snap ring.

Fig 22: Removing Snap Ring
Courtesy of FORD MOTOR CO.
Remove the front output shaft.

Fig 23: Removing Front Output Shaft
Courtesy of FORD MOTOR CO.
Remove the front output shaft dust deflector.
Using the special tools, remove the front output shaft front bearing.

Fig 24: Removing Front Output Shaft Front Bearing
Courtesy of FORD MOTOR CO.
Using the special tools, remove and discard the front output shaft yoke-to-flange seal.

Fig 25: Removing Front Output Shaft Yoke-To-Flange Seal
Courtesy of FORD MOTOR CO.
Remove and discard the input shaft seal.
Remove the front output shaft rear bearing.