Aerostar 2WD V6-245 4.0L (1990)
18.
Install driveshaft using scribe marks as a guide to assure correct balance. Refer to Section 05-00 of the appropriate shop manual for the
procedures.
19.
Lower vehicle and fill transmission with fluid, adding as required while running engine.
20.
Check extension housing area for fluid leaks.
AEROSTAR (AWD), RANGER AND EXPLORER (4X4)
1.
Raise the vehicle on a hoist.
2.
If so equipped, remove the nuts, bolts and skid plate from the frame.
3.
Remove the damper from the transfer case, if necessary.
4.
On vehicles equipped with a electronic shift transfer case, remove the wire connector from the feed wire harness at the rear of the transfer case.
First squeeze the locking tabs, then pull the connector apart.
CAUTION: DO NOT PULL DIRECTLY ON THE WIRES OR PULL OUTWARDLY ON THE LOCKING TABS.
5.
On vehicles equipped with a electronic shift transfer case, remove the connector for the transfer case motor from the mounting bracket.
6.
On vehicles equipped with a manual shift transfer case, disconnect the shift linkage as described in Section 07-06 of the appropriate shop manual.
NOTE:
For detailed instructions on front and rear driveshaft removal and installation, refer to Section 05-01, Driveshaft.
7.
On Ranger and Explorer vehicles, disconnect the front driveshaft from the transfer case front output shaft yoke and wire the driveshaft out of the
way.
On Aerostar vehicles, remove the band clamp from the front driveshaft slip yoke and pull the boot away from the transfer case so the transfer case
can be removed with the driveshaft still connected to the front drive axle.
8.
On Ranger and Explorer vehicles, disconnect the rear driveshaft from the transfer case rear output shaft flange and wire the driveshaft out of the
way.
On Aerostar vehicles, remove the rear driveshaft.
9.
Disconnect the speedometer driven gear from the transfer case rear cover.
10.
On Aerostar vehicles, remove the transfer case strut which is connected to the engine block and transfer case.
11.
On Ranger and Explorer vehicles, disconnect the vent hose from the mounting bracket.
CAUTION: THE CATALYTIC CONVERTER IS LOCATED BESIDE THE TRANSFER CASE. BE CAREFUL WHEN WORKING
AROUND THE CATALYTIC CONVERTER BECAUSE OF THE HIGH TEMPERATURES GENERATED BY THE
CONVERTER.
12.
Support the transfer case with a suitable transmission jack, Rotunda Number 077-00019 or equivalent.
13.
Remove the five bolts retaining the transfer case to the transmission extension housing.
14.
Slide the transfer case rearward off the transmission output shaft. Remove the transfer case from the vehicle. Remove and discard the gasket
between the transfer case and extension housing.
15.
Support the transmission with a transmission jack.
16.
Remove rear support-to-crossmember attaching bolts or nuts.
17.
Raise transmission slightly and remove rear support from extension housing.
18.
On Ranger and Explorer vehicles, remove transmission shift cable bracket.
19.
Loosen extension housing bolts and allow the transmission fluid to drain.
20.
Remove the bolts and the extension housing.
