Four Wheel Drive Systems: Removal & Installation Ford Explorer III

Item 3: Crossmember Bolt Removal Note

1. Remove the eight crossmember-to-frame bolts.

Scheme 20

Item 5: Crossmember Removal Note

1. Position a suitable transmission jack to the transfer case. Securely strap the transfer case to the jack.

Scheme 21

Item 9: Transfer Case Removal Note

1. Position a suitable transmission jack under the transmission.

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

1. With the transmission in the NEUTRAL position, raise and support vehicle.
2. To remove individual components, only carry out the following steps.
3. Remove the components in the order indicated in the following illustration and table.

Scheme 28

Scheme 29

1. Remove the rear drive shaft. For additional information, refer to «DRIVELINE SYSTEM»(ref-194029) .
2. Index-mark the rear output shaft flange to the rear output shaft.
3. Using the special tool to hold the rear output shaft flange, remove the nut.

Scheme 30

1. Using the special tool, remove the rear output shaft oil seal.

Item 6: Rear Output Shaft Speed Sensor Removal Note

1. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. Remove the connector interlock. Remove the wires.

Use the correct electrical connector pin remover.

Scheme 31

Item 15: Front Output Shaft Speed Sensor Removal Note

1. Remove the front output shaft speed sensor wires from the electrical shift motor connector. Remove the connector interlock. Remove the wires.

Use the correct electrical connector pin remover.

Scheme 32

Scheme 33

1. Using the special tool to hold the rear output shaft flange, install the nut.
2. Install the rear drive shaft. For additional information, refer to «DRIVELINE SYSTEM»(ref-194029) .

Item 4: Rear Output Shaft Oil Seal Installation Note

1. Use the special tool to install the rear output shaft oil seal.

Scheme 34

Item 6: Rear Output Shaft Speed Sensor Installation Note

1. Install the speed sensor.

Item 15: Front Output Shaft Speed Sensor Installation Note

1. Install the speed sensor.

Scheme 35

Scheme 36

1. Remove the components in the order indicated in the following illustration and table.
2. To install, reverse the removal procedure.

Item 1: Instrument Panel Center Finish Panel Removal Note

1. Disconnect the electrical connectors.

Item 2: Mode Select Switch Removal Note

1. Disengage the locking tangs and remove the MSS from the instrument panel center finish panel.

Scheme 37

Scheme 38

Scheme 39

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY AND CHARGING SYSTEM»(ref-194056) .
2. Press in on the glove compartment at the points shown and lower the glove compartment.
3. Remove the 4WD control module. Disconnect the 4WD control module electrical connectors. Remove the two screws.
4. To install, reverse the removal procedure.

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Removal and Installation

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

1. Using the special tool, secure the transfer case to a bench.
2. Remove the dampener.
3. If not done previously, remove the drain plug and drain the fluid.
4. Index-mark rear output shaft flange and the upper output shaft.
5. Remove the components in the order indicated in the following illustration and table.
6. To assemble, reverse the disassembly procedure.