Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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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-DEMANDNOTES
2009 Mercury Mountaineer 4.6 8, RWD
Transfer Case - 2-Speed Torque-On-Demand: Notes
2009 Mercury Mountaineer 4.6 8, RWDSECTION Notes
WARNING: This page is about a different variant/trim than selected.
Special Tools
| Illustration | Tool Name | Tool Number |
|---|---|---|
| Remover, Bearing Cup | 308-047 (T77F-1102-A) | |
| Installer, Wheel Hub Bearing Cup | 204-020 (T73T-1202-A) | |
| Puller, Bearing | 205-D064 (D84L-1123-A) or equivalent | |
| Remover, Stator Bearing | 307-318 (T94P-77001-KH) | |
| Holding Fixture, Drive Pinion Flange | 205-126 (T78P-4851-A) | |
| Installer, Differential Bearing Cup | 308-163 (T88C-77000-FH) | |
| Adapter for 303-224 (Handle) | 205-153 (T80T-4000-W) | |
| Holding Fixture, Transmission | 307-003 (T57L-500-B) | |
| Slide Hammer | 100-001 (T50T-100-A) | |
| Installer, Input Shaft Bearing | 308-085 (T83T-7025-C) | |
| Installer, Input Shaft Oil Seal | 308-186 (T90T-7127-B) | |
| Remover, Bushing | 307-001 (TOOL-1175-AC) or equivalent | |
| Remover, Output Shaft Flange | 307-523 or equivalent | |
| Remover, Oil Seal | 303-409 (T92C-6700-CH) | |
| Installer, Valve Stem Oil Seal | 303-367 (T90P-6510-AH) |
Material
| Item | Specification |
|---|---|
| Motorcraft Transfer Case Fluid XL-12 |
- |
| Silicone Gasket and Sealant TA-30 |
WSE-M4G323-A4 |
| Threadlock and Sealer TA-25 |
WSK-M2G351-A5 |
| Item | Part Number | Description |
|---|---|---|
| 1 | 7177 | Drive sprocket |
| 2 | 7A029 | Drive chain |
| 3 | 7Z112 | Thrust washer |
| 4 | - | Oil pump assembly |
| 5 | 7061 | Rear output shaft |
| 6 | 7100 | High-low collar |
| 7 | 7A398 | Front planetary gear set assembly |
| 8 | 7017 | Input shaft |
| 9 | 7N062 | Hub |
| 10 | 7127 | Bearing |
| 11 | 7917 | Snap ring |
| 12 | 7C108 | Clutch pack assembly |
| 13 | 7H150 | Valve assembly |
| 14 | 7917 | Snap ring |
| 15 | 7G159 | Wave spring |
| 16 | 7R428 | Apply cam |
| 17 | 7A534 | Balls (3 required) |
| 18 | 7G362 | Cam and coil housing assembly |
| 19 | 7G361 | Clutch coil assembly |
| 20 | 7A443 | Thrust bearing |
| 21 | 7025 | Front output shaft rear bearing |
| 22 | 7045 | Clutch coil nut (3 required) |
| 23 | 7G450 | Wheel |
| 24 | 7B215 | Yoke-to-flange oil seal |
| 25 | 7B214 | Rear output shaft flange |
| 26 | 7052 | Output flange oil seal |
| 27 | 7B368 | Output shaft flange washer |
| 28 | 7045 | Rear output shaft flange nut |
| 29 | - | Electrical connector |
| 30 | N800670-S | Shift motor bolt (3 required) |
| 31 | 7G360 | Transfer case shift motor |
| 32 | 7288 | Shifter shaft seal |
| 33 | 7A443 | Transfer case bolt (17 required) |
| 34 | 7005 | Rear transfer case |
| 35 | 7F063 | Electric shift cam, torsion spring and shift shaft assembly |
| 36 | 7240 | Shift rail |
| 37 | 7289 | Reduction shift fork |
| 38 | 7917 | Snap ring |
| 39 | 7L027 | Oil pan magnet |
| 40 | 7A153 | Ring gear |
| 41 | 7005 | Transfer case cover (4.0L with 5R55) |
| 42 | 7B215 | Oil seal |
| 43 | 7B215 | Oil seal |
| 44 | 7061 | Output shaft and flange (front) (4.0L with 5R55) |
| 45 | 7061 | Output shaft and flange (front) (4.6L with 6R60) |
| 46 | 7B215 | Oil seal |
| 47 | 7B215 | Oil seal |
| 48 | 7005 | Transfer case cover (4.6L with 6R60) |
| 49 | 7025 | Bearing |
| 50 | 7917 | Snap ring |
| 51 | - | Spacer |
| 52 | 7177 | Driven sprocket |
| 53 | 7025 | Bearing |
RENDER: 1.0x
NO RELATED
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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.