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HOMESERVICE MANUALSMERCURY2009MOUNTAINEER 4.6 8, RWDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 5 (TRANSFER CASE)DISASSEMBLY AND ASSEMBLYTRANSFER CASE - 2-SPEED TORQUE-ON-DEMANDASSEMBLY
2009 Mercury Mountaineer 4.6 8, RWD

Transfer Case - 2-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 tool, carefully install the shifter shaft seal.
    2. Fig 1: Identifying Special Tool
    GF0027659Courtesy of FORD MOTOR CO.
  2. Using the special tools, press the front output shaft support bearing into the case.
    3. Fig 2: Using Special Tools To Press Front Output Shaft Support Bearing Into Case
    GF0027605Courtesy of FORD MOTOR CO.
  3. Using the special tool, install a new oil seal.
    4. Fig 3: Installing Oil Seal Using Special Tool (308-186)
    GF0027636Courtesy of FORD MOTOR CO.
  4. Using the special tool, install a new oil seal.
    5. Fig 4: Installing Oil Seal Using Special Tool (308-186)
    GF0027637Courtesy of FORD MOTOR CO.
  5. Install the front output shaft and flange and snap ring.
    6. Fig 5: Locating Snap Ring
    GF0027606Courtesy of FORD MOTOR CO.
  6. Using a suitable press and the special tool, install the bushing and the bearing, if removed.
    7. Fig 6: Installing Bushing & Bearing Using A Suitable Press & Special Tool (308-085)
    GF0027660Courtesy of FORD MOTOR CO.
  7. Using a suitable press, install the planetary gear carrier support bearing, if removed.
    8. Fig 7: Installing Planetary Gear Carrier Support Bearing Using A Suitable Press
    GF0027661Courtesy of FORD MOTOR CO.
  8. Install a new snap ring.
    9. Fig 8: Locating Snap Ring
    GF0027655Courtesy of FORD MOTOR CO.
  9. Install the front planetary gear set assembly.
    1. Expand the snap ring.
    2. Position the front planetary gear set assembly and release the snap ring.
    10. Fig 9: Identifying Snap Ring And Front Planetary Gear Set Assembly
    GF0027653Courtesy of FORD MOTOR CO.
  10. Install the shift rail.
    11. Fig 10: Locating Shift Rail
    GF0027652Courtesy of FORD MOTOR CO.
  11. Install the reduction shift fork and the high-low collar as an assembly.
    12. Fig 11: Locating Reduction Shift Fork And High-Low Collar
    GF0027651Courtesy of FORD MOTOR CO.
  12. Install the electric shift cam assembly.
    13. Fig 12: Locating Electric Shift Cam Assembly
    GF0027650Courtesy of FORD MOTOR CO.
  13. Install the pump assembly and the rear output shaft as an assembly.
    14. Fig 13: Locating Rear Output Shaft
    GF0027632Courtesy of FORD MOTOR CO.
  14. Install the thrust washer.
    15. Fig 14: Locating Thrust Washer
    GF0027631Courtesy of FORD MOTOR CO.
  15. Install the oil pan magnet.
    16. Fig 15: Locating Oil Pan Magnet
    GF0027630Courtesy of FORD MOTOR CO.
  16. Install the drive chain and the 2 sprockets as an assembly.
    17. Fig 16: Locating Drive Chain
    GF0027662Courtesy of FORD MOTOR CO.
RENDER: 1.0x

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When to See a Mechanic

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.