Disassembly and Assembly: Notes

CAUTION: Discard all seals after removing them.
1. 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 Using Special Tool
Courtesy of FORD MOTOR CO.
2. Using the special tool, secure the transfer case to a bench.
3. Remove the dampener.
4. Remove the drain plug and drain the fluid, if not done previously.
   • Install the drain plug when finished draining.
     Fig 2: Installing Drain Plug When Finished Draining

     Courtesy of FORD MOTOR CO.
5. Index-mark the rear output flange and the upper output shaft.
   Fig 3: Identifying Index-Marks On Rear Output Flange And Upper Output Shaft

   Courtesy of FORD MOTOR CO.
6. Remove the components in the order indicated in the following illustration and table.
   Fig 4: Identifying Transfer Case Components

   Courtesy of FORD MOTOR CO.
   Fig 5: Transfer Case Components Description

   Courtesy of FORD MOTOR CO.
7. To assemble, reverse the disassembly procedure.