Four Wheel Drive Systems: Other Lincoln Aviator I

Possible Causes

1. circuit 972 (BK/WH)
2. circuit 1203 (BK/LB)
3. 4WD control module
4. circuit 693 (OG)

Scheme 10

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1. circuit 779 (BR)
2. circuit 976 (OG)
3. transfer case clutch
4. 4WD control module

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1. Remove the fill plug and check the fluid level. If the fluid is below the correct level, fill the transfer case with automatic transmission fluid.

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1. Remove the upper radiator fan shroud. For additional information, refer to «ENGINE COOLING»(ref-193003) .
2. Remove the rear driveshaft. For additional information, refer to «DRIVELINE SYSTEM»(ref-192998) .
3. Remove the front driveshaft. For additional information, refer to «DRIVELINE SYSTEM»(ref-192998) .
4. Remove the four bolts and the skid plate, if equipped.
5. Drain the fluid if the transfer case is to be disassembled. For additional information, refer to «TRANSFER CASE DRAINING AND FILLING»(ref-193007-S09535121862005092300000) .
6. Remove the RH and LH heat shield-to-crossmember bolts.
7. Remove the components in the order indicated in the following illustration.
8. To install, reverse the removal procedure.

Item 5: Crossmember Removal Note

Scheme 23

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

Item 9: Transfer Case Removal Note

Scheme 24

1. Position a suitable jack under the transmission.

Item 3: Crossmember Bolt Installation Note

Scheme 25

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

Scheme 26

1. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to «BATTERY & CHARGING SYSTEM»(ref-193018) .
2. Remove the components in the order listed in the following illustration.
3. To install, reverse the removal procedure.

Item 1: Control Assembly Removal Note

Scheme 27

1. Disconnect the electrical connectors.

Item 2: Lower End Cap Assembly Removal Note

Scheme 28

1. Disconnect the electrical connector.

Item 4: Panel Assembly Removal Note

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1. Remove the pushpins.
2. Remove the panel by prying rearward at the top of the panel.

Item 6: Transfer Case Control Module Removal Note

Scheme 31

1. Disconnect the electrical connectors.

Item 1: Control Assembly Installation Note

Scheme 32

1. Connect the electrical connectors.

Item 2: Lower End Cap Assembly Installation Note

Scheme 33

1. Connect the electrical connector.

Item 4: Panel Assembly Installation Note

Scheme 34

1. Install the pushpins.

Item 6: Transfer Case Control Module Installation Note

Scheme 35

1. Connect the electrical connectors.

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1. Remove the transfer case from the vehicle. For additional information, refer to «TRANSFER CASE»(ref-193007-S29481568852005092300000) .
2. Using the special tool, secure the transfer case to a bench.
3. Remove the dampener.
4. Remove the drain plug and drain the fluid, if not done previously. Install the drain plug when finished draining.
5. Index-mark the rear output flange and the upper output shaft.
6. Remove the components in the order indicated in the following illustration.
7. To assemble, reverse the disassembly procedure.

Item 1: Output Flange Nut Disassembly Note

Scheme 43

1. Using the special tool to hold the output flange, remove the nut.

Item 5: Output Flange Oil Seal Disassembly Note

Scheme 44

1. Using the special tools, remove the oil seal.

Item 8: Connector Interlock Disassembly Note

Scheme 45

1. Remove the coil wire pin from the electrical connector. Remove the connector interlock. Remove the coil wire pin. Use electrical connector pin extractor tool.

Item 15: Transfer Case Cover Gear Disassembly Note

Scheme 46

1. Separate the transfer case halves at the transfer case pry bosses.

Item 16: Front Output Shaft Rear Bearing Disassembly Note

Scheme 47

1. Using the special tool, remove the bearing.

Item 18: Rear Output Shaft Support Bearing Disassembly Note

Scheme 48

1. Using the special tool, remove the bearing.

Item 27: Clutch Pack Disassembly Note

1. Remove the clutch pack.

Item 28: Drive Chain Disassembly Note

Scheme 49

1. Remove the drive chain, driven sprocket and drive sprocket as an assembly.

Item 33: Rear Output Shaft Assembly Disassembly Note

1. Remove the rear output shaft, pump assembly, and input shaft as an assembly.

Item 34: Input Shaft Oil Seal Disassembly Note

Scheme 50

1. Using the special tool, remove the oil seal.

Item 35: Front Output Shaft Snap Ring Disassembly Note

Scheme 51

1. Holding the front output shaft, remove the snap ring.

Item 37: Front Output Shaft Oil Seal Disassembly Note

Scheme 52

1. Using the special tools, remove the oil seal.

Item 38: Front Output Shaft Support Bearing Disassembly Note

Scheme 53

1. Using the special tools, remove the bearing.

Item 40: Input Shaft Support Bearing Disassembly Note

Scheme 54

1. Using a suitable press and the special tool, remove the bearing.

Item 1: Output Flange Nut Assembly Note

Scheme 55

1. Using the special tool to hold the rear output flange, install the nut.

Item 5: Output Flange Oil Seal Assembly Note

Scheme 56

1. Using the special tool, install the seal.

Item 13: Transfer Case Bolt Assembly Note

Scheme 57

1. Install the bolts. Tighten them evenly in a star pattern.

Item 15: Transfer Case Cover Assembly Note

1. Apply a 3-mm (1/8-inch) bead of sealant to the transfer case mating surfaces.

Item 16: Front Output Shaft Rear Bearing Assembly Note

Scheme 58

1. Using the special tools, press the bearing into the case.

Item 18: Rear Output Shaft Support Bearing Assembly Note

Scheme 59

1. Using the special tools, press the bearing into the case.

Item 27: Clutch Pack Assembly Note

1. Install the clutch pack assembly.

Item 30: Drive Sprocket Assembly Note

Scheme 60

1. Install the drive chain, driven sprocket and the drive sprocket as an assembly.

Item 33: Rear Output Shaft Assembly Note

1. Install the rear output shaft, pump assembly, and input shaft as an assembly.

Item 34: Input Shaft Oil Seal Assembly Note

Scheme 61

1. Using the special tool, install the oil seal.

Item 37: Front Output Shaft Oil Seal Assembly Note

Scheme 62

1. Using the special tool, install the oil seal.

Item 38: Front Output Shaft Support Bearing Assembly Note

Scheme 63

1. Using the special tools, press the bearing into the case.

Item 40: Input Shaft Support Bearing Assembly Note

1. Using a suitable press, install the bearing onto the input shaft.