Mountaineer AWD V8-4.6L SOHC VIN W (2002)
ALWAYS DISCONNECT THE FRONT DRIVESHAFT FROM THE TRANSFER CASE FIRST. OTHERWISE, THE WEIGHT OF THE
DRIVESHAFT CAN PINCH THE BOOT BETWEEN THE SHAFT AND THE HOUSING AND CAN CAUSE THE BOOT TO TEAR.
CAUTION
TAPE THE BEARING CUPS TO THE DRIVESHAFT TO PREVENT THEM FROM FALLING OFF OF THE SPIDER.
NOTE
THE FRONT DRIVESHAFT CV JOINT IS NOT REPAIRABLE.
7.
Remove the front driveshaft.
8.
Drain the fluid if the transfer case is to be disassembled.
9.
Disconnect the motor electrical connector, if equipped.
10.
Disconnect the vent hose.
11.
Position a suitable jack under the transmission.
12.
Remove the LH heat shield-to-crossmember bolts.
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 3 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).
