1997 Explorer/Mountaineer

Transcription

1 Section B: Transfer Case Control Trac IN-VEHICLE REPAIR 1997 Explorer Workshop Manual Switch, Shift Range Selector Removal 1. Remove and reposition the center instrument panel finish panel (044D70). 1. Remove the screws. 2. Remove and reposition the instrument panel finish panel. 2. Disconnect the electrical connectors. 1. Disconnect the shift range selector switch electrical connector. 2. Disconnect the cigar lighter electrical connectors. 3. Disconnect the electrical connectors. 1. Disconnect the rear heated back light switch electrical connector. 2. Disconnect the rear wiper switch electrical connector (if equipped). 4. Disconnect the radio electrical connector. Switch, Shift Range Selector 2999

2 5. Remove the instrument panel finish panel. 6. Remove the shift range selector switch knob. 7. Remove the shift range selector. 1. Remove the screws. 2. Remove the switch. Installation 1. To install, reverse the removal procedures. Switch, Shift Range Selector 3000

3 Switch, Shift Range Selector 3001

4 Section B: Transfer Case Control Trac IN-VEHICLE REPAIR 1997 Explorer Workshop Manual Motor, Electric Shift Removal WARNING: THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Raise and support the vehicle. Refer to Section Disconnect the electrical shift motor connector. 3. Remove the coil wire from the electrical shift motor electrical connector. 1. Remove the wire connector spacer. 2. Remove the coil wire and pin. Use the proper electrical connector pin remover. 4. Remove the electric shift motor. 1. Remove the four electric shift motor bolts. 2. Remove the electric shift motor. Motor, Electric Shift 3002

5 Installation 1. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. To install, reverse the removal procedure. Motor, Electric Shift 3003

6 Section B: Transfer Case Control Trac IN-VEHICLE REPAIR 1997 Explorer Workshop Manual Seal, Oil Rear Special Service Tool(s) Impact Slide Hammer or equivalent D80L-100-D Seal Remover T77F-1102-A Seal Replacer T96T-7127-A Removal WARNING: THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. With the vehicle in neutral, raise and support the vehicle; refer to Section Index the rear driveshaft yoke to the transfer case companion flange. 3. Index the rear driveshaft to driveshaft rear axle companion flange. Seal, Oil Rear 3004

7 4. Remove the four rear bolts and disconnect the rear driveshaft. 5. Separate the rear driveshaft from the transfer case. 1. Remove the four bolts. 2. Carefully remove the driveshaft. 6. Mark the rear transfer case flange and the rear output shaft for proper assembly. 7. Remove the rear transfer case flange. 1. Remove the nut. 2. Remove the washer. 3. Remove the seal. 4. Remove the rear transfer case flange. Seal, Oil Rear 3005

8 8. Use Seal Remover and Impact Slide Hammer to remove the rear transfer case flange seal. Installation 1. Use Seal Replacer and install the rear transfer case flange seal. 2. Align marks on the transfer case flange and the rear output shaft. 3. Position the rear transfer case flange. 1. Position the rear output flange. 2. Position the seal. 3. Position the washer. 4. Position the nut. Seal, Oil Rear 3006

9 4. Using Companion Flange Holding Tool, tighten the rear output flange nut. 5. Align marks on the driveshaft to driveshaft rear axle companion flange and install bolts. 6. Align marks on driveshaft yoke and transfer case companion flange and install the driveshaft bolts. 7. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Seal, Oil Rear 3007

10 Seal, Oil Rear 3008

11 Section B: Transfer Case Control Trac IN-VEHICLE REPAIR 1997 Explorer Workshop Manual Vehicle Speed Sensor (VSS) Removal WARNING: THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Raise and support vehicle. Refer to Section Remove the vehicle speed sensor (VSS). 1. Remove the VSS electrical connector. 2. Remove the VSS nut. 3. Remove the VSS. 3. Remove the VSS gear. Vehicle Speed Sensor (VSS) 3009

12 Installation 1. Install the VSS gear. NOTE: Lubricate the VSS O-ring with Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-BDX-DDX, -QDX or equivalent. 2. Install the VSS. 1. Position the VSS. 2. Install the nut. 3. Install the electrical connector. Vehicle Speed Sensor (VSS) 3010

13 3. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Vehicle Speed Sensor (VSS) 3011

14 Section B: Transfer Case Control Trac IN-VEHICLE REPAIR 1997 Explorer Workshop Manual Gear, Speedometer Drive Removal WARNING: THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. With the vehicle in neutral, raise and support the vehicle; refer to Section Remove the vehicle speed sensor (VSS). 1. Remove the electrical connector. 2. Remove the nut. 3. Remove the VSS. 3. Index the rear driveshaft yoke to transfer case companion flange. 4. Separate the rear driveshaft from the transfer case. 1. Remove the four bolts. 2. Carefully remove the driveshaft. Gear, Speedometer Drive 3012

15 5. Mark the rear transfer case flange and rear output shaft for proper assembly. 6. Using Companion Flange Holding Tool, loosen the rear output flange nut. 7. Remove the rear transfer case flange. 1. Remove the nut. 2. Remove the washer. 3. Remove the seal. 4. Remove the rear transfer case flange. 8. Use the Seal Remover and remove the rear transfer case flange seal. Gear, Speedometer Drive 3013

16 9. Remove the speedometer drive gear. Installation 1. NOTE: Inspect the tone wheel. Install the speedometer drive gear. 2. Use Seal Replacer and install the rear transfer case flange seal. 3. Align marks on the transfer case flange and rear output shaft. 4. Postion the rear transfer case flange. 1. Position the output flange. 2. Position the seal. Gear, Speedometer Drive 3014

17 3. Position the washer. 4. Position the nut. 5. Use Companion Flange Holding Tool, and tighten the rear output flange nut. 6. Align the marks on the rear driveshaft yoke and the transfer case companion flange and install the driveshaft bolts. 7. NOTE: Lubricate the VSS O-ring with Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-BDX, -DDX, -QDX or equivalent. Install the VSS. 1. Position the VSS. 2. Install the nut. 3. Install the electrical connector. Gear, Speedometer Drive 3015

18 8. Install the rear transfer case flange and seal; refer to the procedure in this section. Gear, Speedometer Drive 3016

19 Section B: Transfer Case Control Trac IN-VEHICLE REPAIR 1997 Explorer Workshop Manual Sensor, Output Shaft Speed Front Removal 1. Remove the electric shift motor, refer to the procedure in this section. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. 3. Remove the front output shaft speed sensor wires from the electrical shift motor connector. Use the proper electrical connector pin remover. Installation 1. Install the front output shaft speed sensor. 1. Position the front output shaft speed sensor. 2. Install the bolt. Sensor, Output Shaft Speed Front 3017

20 2. Install the front output shaft speed sensor wires into the electrical shift motor connector. 3. Install the electrical shift motor; refer to the procedure in this section. Sensor, Output Shaft Speed Front 3018

21 Section B: Transfer Case Control Trac IN-VEHICLE REPAIR 1997 Explorer Workshop Manual Sensor, Output Shaft Speed Rear Removal WARNING: THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Raise and support vehicle. Refer to Section Disconnect the shift motor electrical connector. 3. Remove the output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the wire connector spacer. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the rear output shaft speed sensor bolt and remove sensor. Sensor, Output Shaft Speed Rear 3019

22 Installation 1. Install the rear output shaft speed sensor and install the bolt. 2. Install the rear output shaft speed sensor wires into the electrical shift motor connector. 3. Reconnect the shift motor connector. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Sensor, Output Shaft Speed Rear 3020

23 Sensor, Output Shaft Speed Rear 3021

24 Section B: Transfer Case Control Trac IN-VEHICLE REPAIR 1997 Explorer Workshop Manual Damper, Transfer Case Vibration Removal WARNING: THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Raise and support the vehicle. Refer to Section Remove the transfer case vibration damper. 1. Remove the nuts. 2. Remove the transfer case vibration damper. Installation 1. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch, once the vehicle is lowered. Position the vibration damper and install the bolts. Damper, Transfer Case Vibration 3022