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HOMESERVICE MANUALSMERCURY2009MOUNTAINEER 4.6 8, RWDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 5 (TRANSFER CASE)DISASSEMBLY AND ASSEMBLYTRANSFER CASE - 1-SPEED TORQUE-ON-DEMANDASSEMBLY
2009 Mercury Mountaineer 4.6 8, RWD

Transfer Case - 1-Speed Torque-On-Demand: Assembly

2009 Mercury Mountaineer 4.6 8, RWDSECTION Assembly
WARNING: This page is about a different variant/trim than selected.
  1. Using the special tools, press the front output shaft support bearing into the case.
    2. Fig 1: Using Special Tools To Press Front Output Shaft Support Bearing Into Case
    GF0027605Courtesy of FORD MOTOR CO.
  2. Using the special tool, install the oil seal.
    3. Fig 2: Installing Oil Seal Using Special Tool (308-186)
    GF0027636Courtesy of FORD MOTOR CO.
  3. Using the special tool, install the oil seal.
    4. Fig 3: Installing Oil Seal Using Special Tool (308-186)
    GF0027637Courtesy of FORD MOTOR CO.
  4. Install the front output shaft and flange and snap ring.
    5. Fig 4: Locating Snap Ring
    GF0027606Courtesy of FORD MOTOR CO.
  5. Install the pump assembly and the rear output shaft as an assembly.
    6. Fig 5: Locating Rear Output Shaft
    GF0027632Courtesy of FORD MOTOR CO.
  6. Install the thrust washer.
    7. Fig 6: Locating Thrust Washer
    GF0027631Courtesy of FORD MOTOR CO.
  7. Install the oil pan magnet.
    8. Fig 7: Locating Oil Pan Magnet
    GF0027630Courtesy of FORD MOTOR CO.
  8. Install the drive chain and the 2 sprockets as an assembly.
    9. CAUTION: When removing or installing the clutch pack assembly, do not separate the clutch pack assembly. Keep tension on the clutch pack upon removal. Set the clutch pack assembly on the bench in the same position as it was located in the transfer case. The thrust washer in the lower clutch pack uses tabs to hold it in place. If the thrust washer is not in place, a transfer case clearance problem can occur.
  9. Install the clutch pack assembly.
  10. Install a new snap ring.
    11. Fig 8: Locating Clutch Pack Assembly & Snap Ring
    GF0027628Courtesy of FORD MOTOR CO.
  11. Install the wave spring.
    12. Fig 9: Locating Steel Balls & Wave Spring
    GF0027627Courtesy of FORD MOTOR CO.
  12. Install the apply cam and 3 steel balls.
  13. Install the cam and coil housing assembly.
    14. Fig 10: Locating Cam And Coil Housing Assembly
    GF0027626Courtesy of FORD MOTOR CO.
  14. Install the thrust bearing.
    15. Fig 11: Locating Thrust Bearing
    GF0027625Courtesy of FORD MOTOR CO.
  15. Using the special tools and a suitable press, install the front output shaft rear bearing into the case.
    16. Fig 12: Installing Bearing Using Special Tools (205-153, 204-020)
    GF0027607Courtesy of FORD MOTOR CO.
  16. Using the special tools and a suitable press, install the rear output shaft rear bearing into the case.
    17. Fig 13: Installing Bearing Using Special Tools (205-153, 204-020)
    GF0027607Courtesy of FORD MOTOR CO.
  17. Position and support the clutch coil assembly, then install the 3 nuts.
    • Tighten to 10 N.m (89 lb-in).
    18. Fig 14: Locating Clutch Coil Assembly Nuts
    GF0027621Courtesy of FORD MOTOR CO.
RENDER: 1.0x

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Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.