Mountaineer AWD V8-4.6L SOHC VIN W (2002)
13.
Remove the RH heat shield-to-crossmember bolts.
14.
Remove the two nuts and the RH crossmember cover, then remove the four crossmember bolts.
15.
Remove the four LH crossmember bolts.
16.
Remove the transmission mount nuts, then remove the crossmember. It may be necessary to pry the crossmember from the vehicle.
17.
Remove the transmission mount.
18.
Position a suitable transmission jack to the transfer case. Securely strap the transfer case to the jack.
19.
Lower the transmission jacks down just enough to access the upper transfer case-to-transmission bolts, including the bolt retaining the fuel line
bracket. Position the bracket out of the way.
20.
Remove the remaining transfer case-to-transmission bolts. Separate the transfer case from the transmission.
21.
Remove the transfer case from the vehicle. Move the transfer case rearward until the transfer case clears the output shaft. Lower and at the same
time slightly tilt the rear of the transfer case downward.
22.
Clean the transfer case and transmission mating surfaces.
Refer to Transfer Case "DISASSEMBLY AND ASSEMBLY" Section 308-07C to replace Transfer Case Chain.
2002 Mountaineer Transfer Case Installation
1.
Position the transfer case into the vehicle and install the fuel line bracket and the transfer case-to-transmission bolts. Torque bolts to 41 N.m (30
Lb-ft).
2.
Using suitable jacks, raise the transfer case and transmission completely into position.
3.
Remove the transmission jack from under the transfer case.
4.
Install the transmission mount. Torque the mount-to-case bolts to 90 N.m (66 Lb-ft).
5.
Position the crossmember and loosely install the transmission mount nuts.
6.
Install the eight crossmember bolts. Torque to 63 N.m (46 Lb-ft).
7.
Tighten the transmission mount nuts. Torque the mount-to-crossmember bolts to 98 N.m (72 Lb-ft).
8.
Remove the transmission jack from under the transmission.
9.
Install the RH crossmember cover and two nuts. Torque to 9 N.m (80 Lb-in).
10.
Install the RH heat shield-to-crossmember bolts. Torque to 20 N.m (15 Lb-ft).
11.
Install the LH heat shield-to-crossmember bolt. Torque to 20 N.m (15 Lb-ft).
12.
Connect the vent hose.
13.
Connect the shift motor electrical connector, if equipped.
NOTE
DO NOT INSTALL THE FRONT DRIVESHAFT AT THIS TIME. CONTINUE WITH PROCEDURE.
CAUTION
TRANSFER CASE FAILURE CAN RESULT IF THE CORRECT FILL PROCEDURES ARE NOT FOLLOWED.
NOTE
THE FLUID LEVEL MUST BE JUST BELOW THE FILL PLUG.
14.
Remove the fill plug and check the fluid level. If the fluid is below the proper level, fill the transfer case with transmission fluid.
15.
Install the rear driveshaft. For additional information, refer to Workshop Manual Section 205-01.
