Transfer Case - Automatic Shift — Ford Explorer Sport Trac I (2000-2005)

GENERAL SPECIFICATION

Item	Specification
Fluid
MERCON® Multi-Purpose (ATF) Transmission Fluid	XT-2-QDX
Capacity L (Pint)	1.2 (2.5)

General Specification

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Scheme 54: TORQUE SPECIFICATIONS

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Electronic Shift Control System

Four-wheel drive mode is selected using a rotary switch located on the instrument panel. With the vehicle ignition on, the on-board controller verifies and matches the transfer case shift motor position to the switch.

To shift in and out of 4WD low, three conditions must be met.

The automatic transmission must be in NEUTRAL or the manual clutch depressed.
The brake must be applied.
The vehicle speed must be less than 5 km/h (3 mph).

Electric Shift Motor

The motor assembly and connector, mounted externally on the transfer case cover, drives an electric shift cam (7F063) which moves the lockup fork (7289) and the reduction fork assembly (7289) to the selected vehicle drive position. An integral position sensor provides information to the electronic module on the current motor position.

Digital Transmission Range (DTR) Sensor

The DTR sensor is located on the outside of the transmission at the manual lever. The DTR sensor completes the start circuit in PARK and NEUTRAL, the reversing lamp circuit in reverse and the neutral sense circuit (4x4 only) in NEUTRAL. The DTR sensor also sends a digital output signal to the powertrain control module (PCM) indicating the position of the manual lever (P, R, N, D, 2, 1).

Clutch Pedal Position Switch

The clutch pedal position switch is located on the clutch pedal bracket. On vehicles equipped with manual transmissions, the clutch pedal must be fully depressed with the vehicle stopped in order to make a range shift from 4H to 4L, or from 4L to 4H.

Brake Switch

The brake switch is located on the brake pedal. The brake must be depressed in order to make a range shift from 4WD high to 4WD low or back.

Rotary Control Switch

The rotary control switch is located on the instrument panel. The switch consists of a knob with a night time illuminated pointer. The switch is used to select 2WD, 4WD high or 4WD low. The dash indicator light will illuminate when the 4WD high or low position is engaged.

Control Module, Electronic

The electronic control module controls the operation of the transfer case (7005) in response to the inputs from the brake switch, the DTR sensor, the clutch interlock switch, and the motor assembly through the actuation of the rotary control switch.

Transfer Case Power Flow

The Borg-Warner 13-54 Shift Transfer Case provides LOW RANGE driving. This system has no selectable neutral.

In the 4x2 mode, torque from the transmission is transferred to the input shaft (7017), which in turn drives the rear output shaft that drives the rear axle assembly.

The 2W-4W shift is accomplished through the shifting of the lockup collar (7106) that engages the drive sprocket (7177) on the rear output shaft. The drive sprocket turns the drive chain (7A029) which turns the driven sprocket on the front output shaft assembly (7061). The front output shaft assembly then drives the front driveshaft.

The high-low shift is accomplished when the reduction fork assembly moves the reduction hub (7100) to engage the complete carrier assembly (7A398) to the output shaft. Torque from the input shaft assembly is then transmitted through the sun gear (7D063) which then turns the complete carrier assembly. The complete carrier assembly, now engaged to the output shaft, provides the reduction.

The unit is lubricated by a gerotor oil pump assembly (7A149) that channels oil through the bore in the rear output shaft.

Refer to FOUR-WHEEL DRIVE SYSTEMS .

TRANSFER CASE DRAINING & FILLING

Remove the fill plug, and check the fluid level through the fill plug hole. The fluid must be just below the fill plug hole. If necessary, fill the transfer case with MERCON® Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent. The total transfer case fill capacity is 1.2 Liter (2.5 pints).

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Scheme 56: Special Tools

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Scheme 58: Removal

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With the vehicle in NEUTRAL, raise and support the vehicle.
Remove the rear driveshaft. For additional information, refer to «REAR DRIVE SHAFT (4WD)»(/ford/explorer-sport-trac/i-2000-2005/remont/driveshaft-universal-joints/#drive-shafts) in DRIVE SHAFTS article.
Use the special tool to prevent the flange from turning. Remove the nut and the washer (7B368). Discard the nut.
Using a suitable puller, remove the flange.
Remove the oil seal (7052) if it remains on the rear output shaft.
Using the special tool, remove the oil seal (7B215).

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Scheme 61: Installation

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Clean the seal mounting surface.
Using the special tool, install the new oil seal.
Install the oil seal in the flange.
Position the flange on the rear output shaft. If necessary, reseat the oil seal in the flange.
Using the special tool, install the flange. Tighten the nut on the special tool to 54 Nm (40 lb-ft) to seat the flange on the shaft.
Use the special tool to prevent the flange from turning. Install the washer and the new nut.
Connect the driveshaft to the transfer case and install the bolts.
Check, and if necessary, fill the transfer case to the correct level with the specified fluid. For additional information, refer to «TRANSFER CASE DRAINING & FILLING»(/ford/explorer-sport-trac/i-2000-2005/remont/transfer-case/#transfer-case-automatic-shift__transfer-case-draining-filling) .
Lower the vehicle.

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Scheme 64: Special Tools

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Scheme 65: Removal

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With the vehicle in NEUTRAL, raise and support the vehicle.
Disconnect the rear driveshaft from the transfer case and position the driveshaft aside. Index-mark the front flange on the driveshaft and the flange on the transfer case. Remove and discard the four bolts. Disconnect the driveshaft from the transfer case and position the driveshaft aside.
Use the special tool to prevent the flange from turning. Remove the nut and the washer (7B368). Discard the nut.
Using a suitable puller, remove the flange.
Remove the oil seal (7052) if it remains on the rear output shaft.

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Scheme 67: Installation

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Install the oil seal in the flange.
Position the flange on the rear output shaft. If necessary, reseat the oil seal in the flange.
Using the special tool, install the flange. Tighten the nut on the special tool to 54 Nm (40 lb-ft) to seat the flange on the shaft.
Use the special tool to prevent the flange from turning. Install the washer and the new nut.
Connect the driveshaft to the transfer case and install the bolts.
Lower the vehicle.

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Scheme 69: Removal & Installation

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Raise and support the vehicle.
Disconnect the transfer case harness connector.
Remove the two bolts retaining the harness to the motor assembly and connector.
Remove the rear bolt.
Remove the remaining front bolt and the motor assembly and connector. Note the position of the triangular shaft extending out of the transfer case cover.
Clean the mating surfaces of the motor and the transfer case cover.
To install, reverse the removal procedure. Apply a thin coat of Ultra Silicone Sealant F7TZ-19554-AA or equivalent to the motor housing base.

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Scheme 73: Special Tools

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Scheme 77: Transfer Case Disassembled View

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Scheme 82: Disassembling Transfer Case

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Remove the transfer case (7005) from the vehicle. For additional information, refer to «TRANSFER CASE»(/ford/explorer-sport-trac/i-2000-2005/remont/transfer-case/#transfer-case-automatic-shift) .
Attach the transfer case to the special tool.
Use the special tool to prevent the flange from turning. Remove the nut and the washer (7B368). Discard the nut.
Using a suitable puller, remove the flange.
Remove the oil seal (7052) if it remains on the rear output shaft.
Using the special tool, remove the oil seal (7B215).
Remove the spacer (7072).
Remove the two bolts retaining the to the motor assembly and connector.
Remove the rear bolt.
Remove the front bolt and the motor assembly and connector.
Remove the bolts that retain the transfer case cover to the transfer case.
Remove the bolts that retain the transfer case to the transfer case cover.
Insert a breaker bar between the pry bosses, and separate the transfer case cover from the transfer case.
Remove the snap ring that retains the bearing (7025) in the case.
Using the special tools, remove the bearing.
Using the special tools, remove the needle bearing (7127).
Remove the following: Remove the shift collar hub (7100). Remove the return spring (7219). Remove the lockup collar (7106) and the lockup fork (7289) as an assembly. Remove the electric shift cam assembly. Remove the shift rail (7240).
Remove the snap ring.
Remove the lockup hub (7D164) and the sleeve return spring (7D126) from the lockup collar.
Remove the snap ring and the spacer (7119).
Remove the drive chain, the driven sprocket, and the drive sprocket (7177) as an assembly.
Remove the magnet (7E290) and the oil strainer (7A098) from the slot in the transfer case.
Remove the rear output shaft (7061) and the pump assembly (7A149) as an assembly.
Rotate the pump assembly to align the keyway in the cover and the spring pin (7B362) in the rear output shaft, and separate the pump from the shaft.
Remove the snap ring.
Remove the front output shaft assembly.
Remove the reduction fork assembly (7289) and the reduction hub (7100) as an assembly.
Remove the six bolts retaining the front adapter assembly (7050) to the case.
Remove the front adapter assembly, the input shaft assembly (7017), and the complete carrier assembly (7A398) as an assembly.
Using snap ring pliers, expand the tangs of the large snap ring and remove the complete carrier assembly and the input shaft assembly from the front adapter.
Remove the large snap ring from the front adapter.
Using a suitable tool, remove the oil seal (7B215) from the front adapter.
Remove the snap ring.
Using the special tool and a suitable press, remove the bearing (7025).
Remove the thrust washer (7A358) and the input shaft assembly.
Remove the snap ring, the thrust plate (7B066), and the sun gear (7D063).
Using the special tools and a suitable press, remove the needle bearing and the sleeve bearing from the input shaft.
Using a suitable tool, remove the oil seal (7B215).
Remove the snap ring retaining the bearing (7025) to the case.
Using the special tools, remove the bearing.
Using a suitable tool, remove the oil seal (7B216).
Remove the shift fork facings (7C430).
Remove the electric shift cam (7F063) from the shift shaft (7N095).
Remove the torsion spring (7W074) and the spacer (7Z112) from the shift shaft.

Assembly

Note. Prior to assembly, lubricate all parts with MERCON® Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent.

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Scheme 120: Assembly

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Using the special tools and a suitable press, install the bearing.
Install the snap ring.
Using the special tool, install the oil seal.
Using the special tools and a suitable press, install the needle bearing.
Using the special tools and a suitable press, install the sleeve bearing.
Install the sun gear, the thrust plate, and the snap ring.
Install the input shaft assembly and the thrust washer.
Using a suitable press, install the bearing.
Install the snap ring.
Using the special tool, install the oil seal.
Install the large snap ring in the groove in the front adapter.
Apply a 3-mm (1/8-inch) bead of silicone sealant to the front adapter mounting surface of the transfer case. Use Ultra Silicone Sealant F7TZ-19554-AA or equivalent.
Position the front adapter on the transfer case, and install the six bolts.
Install the input shaft assembly and the complete carrier assembly as an assembly. Align the pinion gears gear teeth and the ring gear teeth. Expand the snap ring and push inward on the planet carrier until the input shaft assembly seats fully in the front adapter. Verify that the snap ring engaged the assembly by holding the front adapter and lightly tapping the face of the input shaft assembly against a wooden block.
Attach the front case to the special tool.
Install the new shift fork facings. Verify that they snap securely into place.
Install the reduction hub and the reduction fork assembly as an assembly.
Install the pump assembly on the rear output shaft. Align the keyway in the cover and the spring pin in the rear output shaft and fully seat the pump assembly on the shaft. The shaft will rotate freely in the pump assembly when the pump assembly is fully seated.
If the pump assembly does not turn freely, realign the keyway and the spring pin and jiggle the pump assembly until it seats fully and rotates freely on the shaft.
Prime the pump assembly. Submerge the pump in a container full of clean MERCON® Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent.
Install the rear output shaft and the pump assembly.
Install the oil strainer and the magnet in the slot in the case.
Install the front output shaft assembly.
Install the snap ring.
Install the drive chain, the drive sprocket, and the driven sprocket as an assembly.
Install the spacer and the snap ring.
Install the shift rail through the reduction shift fork. Verify that the shift rail seats in the case bore.
Slide the spacer and the torsion spring on the shift shaft and position it beneath the drive tang.
Position the first spring tang to the left of the drive tang.
Wind the second spring tang clockwise past the drive tang, and push the torsion spring and sleeve in as far as it will go.
Install the electric shift cam, and slide the drive tang between the torsion spring tangs as far as it will go.
Install the pin on the end of the shift shaft into the hole in the case.
Position the torsion spring tangs so that they point toward the top side of the case and just touch the reduction shift fork.
Assemble the lockup assembly.
Press downward on the lockup hub and install the snap ring.
Install the lockup fork and the lockup collar as an assembly.
The triangular shaft will be in the two-wheel high (2H) position at final assembly.
Lift upward on the lockup fork slightly while holding down on the shift rail and rotate the electric shift cam track into the cam roller by turning the shift shaft.
Install the shift collar hub and the return spring.
Using the special tools and a suitable press, install the needle bearing.
Using the special tools and a suitable press, install the bearing.
Install the snap ring that retains the bearing to the transfer case cover.
Using the special tool, install the oil seal.
Apply a 3-mm (1/8-in) bead of silicone sealant to the mating surface of the front case. Use Ultra Silicone Sealant F7TZ-19554-AA or equivalent.
Assemble the cases. Align the output shaft, the shift shaft, and the return spring to their respective bores in the transfer case cover.
Install the bolts.
Install the bolts.
Install the spacer on the rear output shaft.
Using the special tool, install the oil seal.
Install the oil seal in the flange.
Position the flange on the rear output shaft. If necessary, reseat the oil seal in the flange.
Using the special tool, install the flange. Tighten the nut on the special tool to 54 Nm (40 lb-ft) to seat the flange on the shaft.
Use the special tool to prevent the flange from turning. Install the washer and the new nut.
If the shift shaft will not stay in the 4H position, rotate the shift shaft clockwise to the 2H position. During motor assembly and connector installation, rotate the motor assembly counterclockwise until the motor assembly aligns with the mounting holes.
Apply a thin coat of silicone sealant to the base of the motor housing. Use Ultra Silicone Sealant F7TZ-19554-AA or equivalent.
Install the motor assembly and connector.
Install the transfer case (7005). For additional information, refer to «TRANSFER CASE»(/ford/explorer-sport-trac/i-2000-2005/remont/transfer-case/#transfer-case-automatic-shift) .

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Scheme 161: TRANSFER CASE

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With the vehicle in NEUTRAL, raise and support the vehicle.
Remove the skid plate.
Disconnect the transfer case harness connector and position it aside.
If transfer case (7005) disassembly is necessary, remove the drain plug and drain the fluid. Install the drain plug when all of the fluid has drained.
Disconnect the front driveshaft from the transfer case and position the driveshaft aside. Index-mark the front output shaft assembly and the front driveshaft constant velocity (CV) joint. Remove and discard the bolts and washers. Disconnect the front driveshaft from the transfer case and position the driveshaft aside.
Remove the rear driveshaft. For additional information, refer to «REAR DRIVE SHAFT (4WD)»(/ford/explorer-sport-trac/i-2000-2005/remont/driveshaft-universal-joints/#drive-shafts) in DRIVE SHAFTS article.
Disconnect the vent hose.
Position a high lift jack under the transfer case.
Remove the transfer case from the vehicle. Remove the five bolts retaining the transfer case to the extension housing. Slide the transfer case rearward and off of the transmission output shaft. Remove and discard the front extension housing gasket (7086), and clean the mating surfaces.

To install, reverse the removal procedure.
Check and, if necessary, fill the transfer case with the specified type and quantity of fluid. For additional information, refer to «TRANSFER CASE DRAINING & FILLING»(/ford/explorer-sport-trac/i-2000-2005/remont/transfer-case/#transfer-case-automatic-shift__transfer-case-draining-filling) .

Transfer Case - Automatic Shift Ford Explorer Sport Trac I