Ranger 2WD V6-245 4.0L (1990)
21.
Remove the parking pawl and return spring. See Figure 1. Discard the spring.
22.
Install original park pawl and new return spring (from kit) in the extension housing and preload.
23.
Using a new gasket from the kit, position the extension housing on the case, making sure to correctly seat the park pawl actuating rod in the guide
cup bore in the extension.
24.
Install six extension housing retaining bolts. Tighten to 37-52 N-m (27-38 ft.lbs).
25.
On Ranger and Explorer vehicles, install transmission shift cable bracket.
26.
Install rear support and lower transmission.
27.
Install attaching bolts. Torque to 20-30 ft.lbs. Remove the transmission jack.
28.
Place a new gasket (from kit) on the front mounting face of the transfer case assembly. If necessary, apply a small amount of grease to the gasket
to hold it in place during assembly.
29.
On Aerostar vehicles, clean the splines of the front output shaft. Apply 5-8 grams of Long-Life Lubricant, C1AZ-19590-BA (ESA-M1C75-B) or
equivalent to the splines.
30.
Raise the transfer case with the transmission jack so that the transmission output shaft aligns with the splined transfer case input shaft. On
Aerostar vehicles, be sure to align the front driveshaft to the transfer case front output shaft. Slide the transfer case forward onto the transmission
and dowel pin. Install the five transfer case retaining bolts to the extension housing. Tighten the bolts to 34-48 N-m (23-35 ft.lbs). Refer to
Section 07-07 of the appropriate shop manual for the bolt torque sequence.
31.
Remove the transmission jack from the transfer case.
32.
On Ranger and Explorer vehicles, install the vent hose. Make sure the white marking on the hose aligns with the notch in the mounting bracket.
33.
Connect the speedometer driven gear to the transfer case rear cover. Tighten the screw to 2.3-2.8 N-m (20-25 in.lb).
34.
On Ranger and Explorer vehicles, connect the rear driveshaft to the transfer case output shaft flange. Tighten the bolts to 83-118 N-m (61-87 ft.lb).
On Aerostar vehicles, install the rear driveshaft and tighten the bolts to 83-118 N-m (61-87 ft.lb).
35.
On Aerostar vehicles, install the boot on the driveshaft. Be sure to use the new dust boot-to-transfer case clamp (from kit). Refer to Section 05-01
of the appropriate shop manual for the procedures.
36.
On vehicles equipped with a electronic shift transfer case, attach the connector for the transfer case motor to the mounting bracket.
37.
On vehicles equipped with a manual shift transfer case, reconnect the shift linkage as described in Section 07-06 of the appropriate shop manual.
38.
On vehicles equipped with a electronic shift transfer case, connect the electrical connectors to the rear of the transfer case. Make sure the tabs on
the connectors are in the locked position.
39.
Remove the transfer case fill plug and check the fluid level. Add Motorcraft Mercon XT-2-QDX or DDX Automatic Transmission fluid
E4AZ-19582-B (ESP-M2C-166-11) or equivalent to the bottom of the fill hole, if required.
40.
On Ranger and Explorer vehicles, install the damper, (if previously removed). Tighten the bolts to 34-48 N-m (25-35 ft.lb).
41.
On Aerostar vehicles, install the transfer case strut. Tighten the bolt at the engine block end of the strut to 61-81 N-m (45-60 ft.lb) and the nut at
the transfer case end to 75-88 N-m (55-65 ft.lb).
42.
Install the skid plate, if so equipped. Tighten the bolts and nuts to 20-27 N-m (15-20 ft.lb).
43.
Lower the vehicle.
44.
Check transmission fluid level. Add fluid as required.
Shift Cable Spring Installation
The shift cable is to be modified by the addition of a spring to remove cable free-play from the adjustment procedure.
