Transfer Case - Automatic Shift: Other Ford Expedition II

Shifting Between 2WD, A4WD and 4WD HIGH

The operator can switch between 2WD, A4WD and 4WD HIGH mode at any speed.

Shifting Into/Out of LOW RANGE

When shifting into or out of LOW RANGE, the 4WD control module requires that the vehicle speed is less than 5 km/h (3 mph), the brake is applied, and the transmission is in NEUTRAL.

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Refer to FOUR WHEEL DRIVE SYSTEMS .

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MATERIAL SPECIFICATION

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1. Remove the drain plug and drain the fluid. Clean the drain plug and the drain plug area. Apply pipe sealant to the drain plug threads, then install the drain plug.
2. Clean the area around the fill plug. Remove the fill plug.
3. Using the special tool, fill the transfer case to specification. The fluid must be just below the fill plug hole. Fill the case until the fluid slowly flows over the fill plug threads. Clean the fluid from the fill plug area.
4. Apply pipe sealant to the fill plug threads, then install the fill plug.

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1. Position the vehicle on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-209881) .
2. Remove the rear driveshaft. For additional information, refer to «DRIVESHAFT»(ref-209889) .
3. Using a suitable tool, remove the oil seal.

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1. To install, reverse the removal procedure. Using the special tool, install the oil seal.

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Material

MATERIAL SPECIFICATION

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1. Clean the transfer case exterior with solvent and dry with compressed air.
2. Using the special tool, secure the transfer case to a work bench. Rotate the transfer case so that the output shaft is pointing upward.
3. Drain the fluid from the transfer case, if not done previously.
4. Using a suitable tool, remove and discard the oil seal.
5. Remove the coil wire pin from the electrical connector. Remove the wire connector spacer. Remove the coil wire pin (tan wire). Use an electrical connector pin extractor tool.
6. Remove the bolts and transfer case shift motor.
7. Remove the three coil nuts and washers.
8. Remove the 20 bolts.
9. Separate the transfer case halves. Use the pry bosses to separate the case halves.
10. Using the special tools, remove the rear output shaft support bearing.
11. Using the special tools, remove the front output shaft rear bearing.
12. Remove the snap ring. Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
13. Remove the caged thrust bearing assembly. Inspect the bearing for wear or damage. Install a new bearing as necessary.
14. Remove the cam/coil housing.
15. Remove the steel balls and the cam.
16. Remove the wave spring.
17. Remove and discard the snap ring.
18. Remove the lockup shift fork spring.
19. Remove the clutch pack assembly.
20. Remove the drive chain and the sprockets as an assembly. Inspect the drive chain for wear or damage. Inspect the sprockets for broken or cracked teeth. Install new components as necessary.
21. Remove the thrust bearing assembly. Remove the thrust washer. The upper thrust washer may be attached to the sprocket. Remove the thrust bearing. Remove the thrust washer. Inspect the washers and bearing for wear or damage. Install new components as necessary.
22. Remove the lockup collar and the lockup fork as an assembly. Separate and inspect the lockup collar and the lockup fork for wear or damage.
23. Remove and clean the oil pan magnet.
24. Remove the output shaft hub.
25. Remove the oil pump assembly.
26. Remove the output shaft.
27. Remove the reduction shift fork, the reduction hub, and the shift cam as an assembly. Separate and inspect the reduction hub and the reduction shift fork for wear or damage.
28. Remove the shift fork shaft.
29. Remove the front planet. Using a drift and a hammer, remove the front planet needle bearing, if necessary.
30. Remove the ring gear. Remove the snap ring. Inspect the snap ring for wear or damage. Install a new snap ring as necessary. Remove the ring gear.
31. Remove the snap ring and the front output shaft. Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
32. Remove and discard the front output shaft oil seal.
33. Remove and discard the front input shaft oil seal.
34. Using a suitable driver, remove the front planet support bearing.
35. Using a suitable driver, remove the front output shaft support bearing.
36. Using a suitable tool, remove and discard the shifter shaft seal.

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1. Lubricate all internal components with the recommended transfer case lubricant during reassembly.
2. Clean the mating surfaces of the cases.
3. Using a suitable press and the special tools, install the front planet support bearing.
4. Using a suitable press and the special tools, install the front output shaft support bearing.
5. Using the special tool, install a new oil seal.
6. Using the special tool, install a new shifter shaft seal.
7. Install the case to the transmission holding fixture. Secure the case to the work bench.
8. Using the special tools, install a new oil seal.
9. Install the ring gear. Position the ring gear in the case. Install the snap ring.
10. Install the front output shaft and the snap ring.
11. Install the front planet.
12. Install the shift fork shaft.
13. Install the reduction shift fork, the reduction hub, and the shift cam as an assembly.
14. Install the output shaft.
15. Install the oil pump assembly. Make sure the oil pump finger is in the slot in the case.
16. Install the oil pan magnet into its slot in the case.
17. Install the output shaft hub.
18. Install the lockup collar and the lockup fork as an assembly.
19. Install the three-piece thrust bearing assembly. Install the thrust washer. Install the thrust bearing. Install the thrust washer.
20. Install the drive chain and the sprockets as an assembly.
21. Install the clutch pack assembly.
22. Install the lockup shift fork spring.
23. Install a new snap ring.
24. Install the wave spring.
25. Install the cam and the steel balls.
26. Install the cam/coil housing.
27. Install the thrust bearing assembly.
28. Install the snap ring.
29. Using a suitable press and the special tool, install the rear output shaft support bearing.
30. Using a suitable press and the special tool, install the front output shaft rear bearing.
31. Apply a bead of silicone sealant to the transfer case mating surfaces, then position the two transfer case halves together. Tighten the bolts evenly in a star pattern. Position the coil studs through the case holes, make sure the shift cam shaft is aligned with its case bore, and the lockup shift fork spring is in position.
32. Install the coil washers and nuts.
33. Using the special tool, install the oil seal.
34. Install the transfer case shift motor.
35. Install the coil wire pin in the electrical connector. Remove the wire connector spacer. Install the coil wire pin. Reinstall the wire connector spacer.
36. Remove the transfer case from the special tool.

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1. With the vehicle in NEUTRAL position the vehicle on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-209881) .
2. Drain the fluid if the transfer case is to be disassembled. Install the drain plug when finished draining.
3. Remove the transfer case-to-transmission brace. Remove the bolts from the transmission. Remove the nuts from the transfer case.
4. Remove the two nuts and the front driveshaft shield.
5. Remove the front driveshaft. For additional information, refer to «DRIVESHAFT»(ref-209889) .
6. Remove the rear driveshaft. For additional information, refer to «DRIVESHAFT»(ref-209889) .
7. Disconnect the electrical connector.
8. Disconnect the vent hose.
9. Using a suitable jack stand, support the transmission.
10. Using a suitable transmission jack, support the transfer case.
11. Remove the two exhaust heat shield-to-crossmember bolts.
12. Remove the crossmember-to-frame nuts and bolts.
13. Remove the transmission mount-to-crossmember nuts, then remove the crossmember.
14. Remove the bolts and the transmission mount.
15. Remove the bolt and the exhaust hanger bracket.
16. Remove the six transfer case-to-transmission extension housing bolts.
17. Separate the transfer case from the transmission extension housing, move the transfer case rearward off the output shaft, then lower the transfer case from the vehicle.
18. Remove the transfer case-to-transmission gasket and clean the mating surfaces.

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1. With the vehicle in NEUTRAL, position the vehicle on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-209881) .
2. Drain the fluid if the transfer case is to be disassembled. Install the drain plug when finished draining.
3. Remove the two nuts and the front driveshaft shield.
4. Remove the front driveshaft. For additional information, refer to «DRIVESHAFT»(ref-209889) .
5. Remove the rear driveshaft. For additional information, refer to «DRIVESHAFT»(ref-209889) .
6. Disconnect the electrical connector.
7. Disconnect the vent hose.
8. Remove the bolts and the damper.
9. Using a suitable transmission jack, support the transfer case.
10. Remove the six transfer case-to-transmission extension housing bolts.
11. Separate the transfer case from the transmission extension housing, move the transfer case rearward off the output shaft, then lower the transfer case from the vehicle.
12. Remove the transfer case-to-transmission gasket and clean the mating surfaces.

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1. To install, reverse the removal procedure. Install a new transfer case-to-transmission gasket. Fill the transfer case. For additional information, refer to «TRANSFER CASE DRAINING AND FILLING»(ref-209915-S19751077022005121200000) when refilling the transfer case. Refer to «SPECIFICATIONS»(ref-209915-S26555215652005121200000) for the correct type and quantity of fluid. Tighten the transfer case-to-transmission bolts evenly in a star pattern.