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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-DEMANDDISASSEMBLY
2009 Mercury Mountaineer 4.6 8, RWD

Transfer Case - 2-Speed Torque-On-Demand: Disassembly

2009 Mercury Mountaineer 4.6 8, RWDSECTION Disassembly
WARNING: This page is about a different variant/trim than selected.
  1. Remove the transfer case. For additional information, refer to Transfer Case .
  2. Using the special tool, secure the transfer case to the bench.
    3. Fig 1: Securing Transfer Case To Bench
    GF0027619Courtesy of FORD MOTOR CO.
  3. Remove the 3 heat shield bolts, then remove the heat shield.
    4. Fig 2: Locating Heat Shield Bolts
    GF0027640Courtesy of FORD MOTOR CO.
  4. If not previously done, remove the drain plug and drain the fluid.
    • When finished draining, install the drain plug and tighten to 20 N.m (15 lb-ft).
    5. Fig 3: Locating Drain Plug
    GF0027641Courtesy of FORD MOTOR CO.
  5. Using the special tool to hold the output flange, remove the rear output shaft flange nut.
    6. Fig 4: Removing/Installing Nut Using Special Tool (205-126) To Hold Output Flange
    GF0027642Courtesy of FORD MOTOR CO.
  6. Remove the output shaft yoke washer.
  7. Using the special tool, remove the output flange.
    8. Fig 5: Removing Output Flange Using Special Tool (307-523)
    GF0027643Courtesy of FORD MOTOR CO.
  8. Remove and discard the output flange oil seal.
    9. Fig 6: Locating Output Flange Oil Seal
    GF0027644Courtesy of FORD MOTOR CO.
  9. Using the special tools, remove and discard the yoke-to-flange seal.
    10. Fig 7: Removing Rear Output Shaft Oil Seal Using Special Tools (100-001, 307-001)
    GF0027580Courtesy of FORD MOTOR CO.
  10. Remove the connector interlock. Using a electrical connector pin extractor tool, remove the coil wire pin from the electrical connector.
    11. Fig 8: Locating Coil Wire Pin
    GF0027645Courtesy of FORD MOTOR CO.
  11. Remove the 4 transfer case shift motor bolts.
  12. Remove the transfer case shift motor.
    13. Fig 9: Locating Transfer Case Shift Motor Bolts
    GF0027646Courtesy of FORD MOTOR CO.
  13. Remove the 17 transfer case bolts.
    14. Fig 10: Locating Transfer Case Bolts
    GF0027620Courtesy of FORD MOTOR CO.
  14. Remove the 3 clutch coil assembly nuts.
    15. Fig 11: Locating Clutch Coil Assembly Nuts
    GF0027621Courtesy of FORD MOTOR CO.
  15. Separate the transfer case halves at the transfer case pry bosses.
    16. Fig 12: Separating Transfer Case Halves At Transfer Case Pry Bosses
    GF0027622Courtesy of FORD MOTOR CO.
  16. Remove the snap ring, then using the special tool, remove the rear output shaft support bearing.
    17. Fig 13: Locating Rear Output Shaft Support Bearing And Special Tool
    GF0027623Courtesy of FORD MOTOR CO.
  17. Using the special tool, remove the front output shaft rear bearing.
    18. Fig 14: Locating Front Output Shaft Rear Bearing And Special Tool
    GF0027624Courtesy of FORD MOTOR CO.
  18. Remove the thrust bearing.
    19. Fig 15: Locating Thrust Bearing
    GF0027625Courtesy of FORD MOTOR CO.
  19. Remove the cam and coil housing assembly.
    20. Fig 16: Locating Cam And Coil Housing Assembly
    GF0027626Courtesy of FORD MOTOR CO.
  20. Remove the apply cam and 3 steel balls.
  21. Remove the wave spring.
    22. Fig 17: Locating Steel Balls & Wave Spring
    GF0027627Courtesy of FORD MOTOR CO.
  22. Remove the snap ring.
    23. Fig 18: Locating Clutch Pack Assembly & Snap Ring
    GF0027628Courtesy 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.