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Transfer case removal and installation - 2003 Lincoln Aviator

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I want to replace my transfer case for a 2006 Ford escape. Can you tell me or give me so information how to do it


You need to raise the truck off all four wheels the remove the rear drive shaft then remove the front drive shaft .Next drain the fluid from the transfer case . next reinstall drain plug. Now use a jack and a flat piece of wood and slightly jack up un the bottom of the transmission to take the weight off the crossmember . Next remove the croosmember brace after removing that and supporting the transmission you can start removing the wiring and contols on the transfer case after dissconecting all that now you can remove the bolts from the transmission to the transfer case , remove all but one easy to get to lower one ( you choose) now start taking the last bolt out while holding the transfer to the transmission .( two people here helps) once you have removed the last bolt slide the transfer case back torwards the rear end some fluid may come out once you seperate these two be ready to catch it with a drain pan . you slide the transfer off the transmission out put shaft and it out . flow the step inreverse to install don't forget to refill the new transfer case with fluid and check the transmission fluid level once you have lowerd the truck back down.

May 15, 2011 | 2006 Ford Escape

2 Answers

I am wanting to install a transmission in a 1998 jeep wrangler se. 4.0 cyl 2.5 liter I will need to take out the old one first. I've never done it before and any help would be great


Instructions vary depending upon if its a stick or automatic transmission. Your best bet if you haven't ever done anything like that is to get yourself a chilton or haynes manual. Both have text and pictures to help with the job. With hanynes, you may need the transmission manual instead of the regular repair one if its an automatic...check the contents before you buy it.
When doing an automatic, it's advisable to remove the crank sensor from the bellhousing as often they get damaged accidentally when working in there. If you need to remove the flywheel, make sure you mark it's position so you can put it back exactly the same way it was installed.
Make sure you have a flat solid area to work on. Transmissions need to be supported so notheing get's damaged. To do that, you need a place where you can move a jack easily. If you need to work on dirt etc, buy a sheet of 5/8" plywood to put underneath.

Mar 25, 2011 | 1998 Jeep Wrangler

1 Answer

Where is the transfer case shift motor located on 2004 dodge dakota


The transmission control module and the transfer case control module are separate parts. The transmission control module is mounted under the hood and controls only transmission functions. The transfer case control module controls only the transfer case, and is located inside the truck. If you remove the trim panel under the steering column you will find the transfer case control module mounted just to the right of the opening.


The shift motor is located just behind the axle tube to prevent damage.
There is a shift motor on the right front axle that is vacuum operated.
The shift motor (1) is an electromechanical device consisting of a DC permanent magnet motor, a motor brake, a gear train and an analog position sensor. The shift motors' overall function is to move and lock a gear that moves the mode fork found in the transfer case. This allows the transfer case to be shifted electrically to multiple operating positions (4LOCK and AWD). The operating current of the shift motor under
stall conditions is 30 amps maximum at 72° F with 13.5 volts, at the motor leads.
OPERATION
Shifting in the transfer case occurs when the shift motor brake is released and a Pulse Width Modulated (PWM) voltage is supplied to the shift motor by the Front Control Module (FCM). A linear analog position sensor located inside the shift motor, provides the FCM with the motors' angular, rotational position. With this information, the FCM
continuously knows the motors' position, and therefore allows it to accurately control the motors' operation, including voltage polarity which is used to control motor direction.

REMOVAL :---Note: New shift motor assemblies are shipped in the AWD position. If a new shift motor assembly must be installed, it will be necessary to shift the transfer case to the AWD position prior to motor installation.
Raise the vehicle on a suitable hoist.Remove the front propeller shaft. Disengage the wiring connectors from the shift motor and mode sensor.Remove the front output shaft companion flange from the transfer case.Remove the bolts (Remove the Shift Motor and Mode Sensor Assembly Bolts) holding the shift motor and mode sensor assembly onto the transfer case.Separate the shift motor and mode sensor assembly from the transfer case. See fig below:-- helpmech_19.gif
1 - TRANSFER CASE.2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY.3 - BOLT.-- This should help.Thanks.Helpmech.

Feb 26, 2011 | 2004 Dodge Dakota

2 Answers

I need instructions on replacing the clutch in a '94 Chevy Blazer 4x4, 350 engine. Specifically the pilot bearing, throwout bearing.


The pilot bearing is pressed into the flywheel and you need a pilot bearing/bushing puller. Some A/P stores will rent it to you for free (deposit). the throwout bearing is held onto the clutch fork normally by clips. Sometimes you have to take the "fork" out to get the bearing off.

Make sure to note how "deep' the pilot bearing/bushing is so that when you install the new one it is set at the right depth.

Jan 01, 2011 | Chevrolet Blazer Cars & Trucks

1 Answer

Removal of front right axle from a jaguar 2002 x-type


Loosen the wheel hub nut.
Remove the front road wheel and tire.
Remove the tie rod end retaining nut.
Using the special tool 204-192 Ball joint Splitter
detach the tie rod end.
Remove the subframe reinforcement plate retaining bolts.
Loosen the subframe rear mount bolt.
Loosen the subframe front mount bolt.
Remove and discard the wheel hub nut.
using spcial tools 204-269Forcing Screw,205-491-01 adapter nuts,205-491 wheel hub puller
Detach the wheel knuckle.
Remove the lower arm ball joint retaining bolt.
Reposition the lower arm.
Detach the wheel knuckle.
using special tools 307-443 RH Halfshaft splitter ,307-442 RH Halfshaft splitter handle
detach the halfshaft.
Remove the exhaust muffler inlet pipe.
Remove the halfshaft seal.
Remove the transfer case Y bracket retaining bolt.
To prevent damage to the transfer box internal seal,
make sure that the link shaft is not retracted further than
200 mm from the transfer box casing.
remove the halfshaft.
Attach special tools to the halfshaft.
Lever the special tools to displace the halfshaft.
Install the transfer case Y bracket retaining bolt.
Remove the halfshaft.
Use suitable protective covers to protect the barshaft.
Remove the halfshaft snap ring.
Install a new snap ring to the halfshaft.
Install a new halfshaft seal.
Remove the special tool.
Remove the transfer case Y bracket retaining bolt.
Remove the special tool.
Make sure the CV joint splines are located fully.
Do not use excessive force when engaging the CV joint into the link shaft.
Install the halfshaft.
Install the transfer case Y bracket retaining bolt.
Tighten to 25 Nm.
Attach the wheel knuckle.
Reposition the lower arm.
Attach the wheel knuckle.
Install the lower arm ball joint retaining bolt.
Tighten to 83 Nm.
Install the exhaust muffler inlet pipe.
Tighten the subframe front mount retaining bolt.
Tighten to 142 Nm.
Loosely install the subframe rear mount retaining bolt.
Install the subframe reinforcement plate retaining bolts.
Tighten to 35 Nm. Tighten to 142 Nm.
Install the tie rod end.
Tighten to 35 Nm.
Loosely install a new wheel hub nut.
Install the front road wheel and tire.
Tighten the wheel hub nut.
Tighten to 330 Nm.
Check the subframe alignment.

May 20, 2010 | 2002 Jaguar X-Type

1 Answer

Transfer case removal


Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide
Transfer Case Assembly - REMOVAL & INSTALLATION

Samurai Models
Even the 2WD Samurai uses a transfer case. Rather than use a straight line driveshaft from the transmission to the differential, the Samurai leaves the transfer case in place and replaces its internal working with a simple offset gear mechanism, thus keeping 2 of the 3 driveshafts used in the 4WD vehicle.
  1. On 4WD vehicles, remove the transfer case shift lever.
  2. Raise and support the vehicle safely.
  3. Drain the oil from the transfer case.
  4. Matchmark and remove the driveshafts from the transfer case assembly. Not all of the driveshafts need to be completely removed from the vehicle, just unbolted from the case flanges. In most cases, the shaft or shafts on one side of the transfer case can be repositioned and supported out of the way.
  5. Support the transfer case using a suitable transmission jack.
  6. Disconnect the speedometer cable from the transfer case.
  7. On 4WD vehicles, disconnect the 4WD switch lead wire at the coupler.
  8. Remove the three mounting bolts and/or nuts securing the transfer case to the chassis, as applicable.
  9. Carefully lower the transfer case from the vehicle.
To install:
  1. Position and install the transfer case. Tighten the mounting bolts to 159-248 inch lbs. (18-28 Nm) and/or the mounting nuts to 19-25 ft. lbs. (25-34 Nm).
  2. On 4WD vehicles, connect the 4WD switch lead wire at the coupler.
  3. Connect the speedometer cable to the transfer case.
  4. Properly refill the transfer case with an approved type of gear oil.
  5. Align and install the driveshafts to the transfer case.
  6. On 4WD vehicles, install the transfer case shift lever.
  7. Remove the jackstands and carefully lower the vehicle.
Sidekick, Tracker, Sidekick Sport and X-90 Models
On these models the transfer case is bolted to the transmission and takes the place of the 2WD transmission's extension housing. Therefore, transfer case is removed or installed as part of the transmission assembly.

Hope this help (remember rated this and comment).

Mar 21, 2010 | 1993 Geo Tracker

1 Answer

How to remove transfer case 2000 blazer???


jack and secure thr truck, remove all linkage and wiring, both drive shafts, block up the transmission, remove suppoet member ust a trans jack to support transfer case, unbolt from trans, carefully pull back and lower, install is reverse

Oct 27, 2009 | 2003 Chevrolet Blazer

1 Answer

I need to know how to install a rear drive chain on a 1992 ford bronco. It's in the transfer case and only drives in 4 low now. The mechanic said its 4 bolts to the transfer case and the chain is right...


It has more than four bolts. You have to remove the drive shaft and all of the linkage from the transfer case including any electrical connections. You can then remove all of the bolts connecting the transfer case to the transmission. After all of the bolts have been removed just remember due to the angle the transfer case is mounted it will try to twist when it is disconnected from the transmission. And keep in mind that the transfer case is HEAVY. Truthfully if you are not a pretty fair mechanic you might want to have a qualified technician do the job for you.Some of the transfer cases Depending on which transfer case you actually have, some of them can be a real pain in the neck to install a chain.

bigc

Jun 29, 2009 | 1992 Ford Bronco

1 Answer

Pictures of removing gearbox and transfer case from vehicle


REMOVAL & INSTALLATION CAUTION
The catalytic converter is located beside the transfer case. Be careful when working around the catalytic converter because of the extremely high temperatures generated by the converter.
  1. Disconnect the negative battery cable.
  2. Raise the vehicle and support it safely.
  3. If so equipped, remove the skid plate from frame.
  4. Drain the transfer case.
  5. Remove the damper from the transfer case, if so equipped.
  6. On electronic shift models, remove the wire connector from the feed wire harness at the rear of the transfer case. Be sure to squeeze the locking tabs, then pull the connectors apart.
  7. Disconnect the front driveshaft from the axle input yoke.
  8. If equipped, loosen the clamp retaining the front driveshaft boot to the transfer case, and pull the driveshaft and front boot assembly out of the transfer case front output shaft.
  9. Disconnect the rear driveshaft from the transfer case output shaft yoke.
  10. If equipped, disconnect the speedometer driven gear from the transfer case rear cover.
  11. If equipped, disconnect the electrical wire harness plug from the Vehicle Speed Sensor (VSS).
  12. Disconnect the vent hose from the mounting bracket.
  13. On manual shift models, perform the following:
    1. Remove the shift lever retaining nut and remove the lever.
    2. Remove the bolts that retains the shifter to the extension housing. Note the size and location of the bolts to aid during installation. Remove the lever assembly and bushing.
  14. If equipped, remove the heat shield from the transfer case.
  15. Support the transfer case with a transmission jack.
  16. Remove the mounting bolts retaining the transfer case to the transmission.
  17. Slide the transfer case rearward off the transmission output shaft and lower the transfer case from the vehicle. Remove the gasket or any old sealer from between the transfer case and the transmission.

Mar 29, 2009 | 1988 Mazda B2600 Cab Plus

1 Answer

Transfer case removal and installation


   You need to remove the skid plate/crossmember (6 3/4 bolts at the frame and 3 nuts at the trans mount.). Support the trans first with a jack and a block of wood before removing. Remove the rear drive shaft from the differential and pull it out of the transfer case. Unbolt the front shaft from the transfer case only and wire to the side with a coat hanger.Disconnect the vacuum connector from the top and the speedo cable. Unbolt the shifter and bracket (tricky operation). unbolt the transfer case from the trans and pry it rearward with a floor jack under it. Reverse operation to install. The 87 used a different case than the 231 from the factory but the 231 will work. You may have a concern with the length of the shift linkage. If you do anyone with a welder can extend it for you. Good luck hope this helps.

Oct 10, 2008 | 1987 Jeep Wrangler

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