Ford Bronco 4WD Transfer Case Disassembly Procedure - Shop Manual Page 6-21

This is page 6-21 from a Ford shop manual, Part 6-3 covering the 4-Wheel Drive Transfer Case, section 3 'Major Repair Operations.' It presents the step-by-step DISASSEMBLY procedure (steps 1–20) for the transfer case, including cleaning the case, removing the retaining plugs, detent springs and balls for the front and rear drive shift rail detent rods, removing the idler shaft lock plate and idler shaft (with a caution not to lose the rollers), removing the flange retaining nuts and flanges from the front and rear output shafts, removing the adapter housing, rear output shaft bearing retainer, shift rails and forks, front output shaft rear cover and shims, bearing retainer and gasket, bearings, cups, sliding gear, main drive gear, and detent rods. Four figures are included: Fig. 3 shows the front and rear drive shift rail detent balls, springs and plugs on the case; Fig. 4 shows removing the idler shaft (thrust washers, shaft, idler gear labeled); Fig. 5 shows removing or installing the flange retaining nut using Tool 4851-K; and Fig. 6 shows removing the flange with Tool T56L-4851-C. Figure reference codes C 1601-A through C 1604-A appear on the illustrations.