1991 1999 ford explorer chilton User Manual

							View of the transmission kickdown cable assemble and its adjusting points
Click to enlarge
Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. HOW TO USE THIS BOOK
792 KICKDOWN CABLE 
						

							
TRANSFER CASE
Identification
View of the Borg-Warner model 13-54 with mechanical shift. Electronic shift and model 44-05 are similar
There are three transfer cases used on the Ranger, Explorer and Mountaineer. There are 2 versions of the Borg
Warner 13-54 (mechanical shift and electronic shift), a Borg Warner 44-05 (Control Trac) and an All Wheel
Drive (AWD) transfer case.
The Borg Warner 13-54, mechanical shift transfer case, is a 3-piece aluminum part time unit. It transfers
power from the transmission to the rear axle and when actuated, also the front drive axle. The unit is
lubricated by a positive displacement oil pump that channels oil flow through drilled holes in the rear output
shaft. The pump turns with the rear output shaft and allows towing of the vehicle at maximum legal road
speeds for extended distances without disconnecting the front and/or rear driveshaft.
The Borg Warner 13-54, electronic shift transfer case, transfers power from the transmission to the rear axle
and also the front drive axle, when electronically actuated.
This system consists of a pushbutton control, an electronic control module, an electric shift motor with an
integral shift position sensor and a speed sensor.
The electric shift motor, mounted externally at the rear of the transfer case, drives a rotary helical cam. The
cam moves the 2WD-4WD shift fork and 4H-4L reduction shift fork to the selected vehicle drive position.
The system has no selectable Neutral (N) setting.
The manufacturer recommends that the Borg Warner 13-54 transfer case equipped vehicles should not
be operated in 4WD (whether HI or LOW) mode on dry pavement. Severe driveline torsional wind-up
will occur, possibly damaging the drivetrain components.
The Borg Warner 44-05 transfer case operates in the same manner as the 13-54, except that it also houses a
transfer case clutch. This clutch, which is controlled by the Generic Control Module (GEM), enables the
vehicle to be driven in 4-wheel drive on dry pavement by cycling the clutch to compensate for different front
and rear driveshaft speeds (as in turning). The system has a dealer installable Neutral (N) position mode.
TRANSFER CASE 793 
						

							
The All Wheel Drive (AWD) transfer case is a 2-piece aluminum, chain driven, viscous clutch type unit. The
AWD transfer case is always active in 4-wheel drive, thus producing a full-time engagement. The viscous
clutch automatically distributes power to both the front and rear wheels, depending on need.
Rear Output Shaft Seal
REMOVAL & INSTALLATION
Remove the rear output shaft seal-slide hammer and seal removal tool shown Click to enlarge
Raise and safely support the vehicle.
1. 
Matchmark the rear driveshaft to the transfer case yoke then disconnect the shaft from the yoke. Wire
the driveshaft up and out of the way.
2. 
Using a 30mm (1.18 in.) thin-wall socket, remove the rear output shaft yoke retaining nut.
3. 
Some fluid may dribble out as the yoke is removed, and then again when the seal is removed. While an HOW TO USE THIS BOOK
794 Identification 
						

							
old rag should suffice for catching the fluid, a small catch can may be better, especially if the vehicle is
not parked level.
Remove the output shaft yoke washer, rubber seal and the yoke from the output shaft.
4. 
Remove the rear output shaft seal by prying and pulling on the curved outer lip of the seal or by using
Impact Slide Hammer Tool T50T-100-A and Seal Remover T74P-77248-A or equivalent. Take
care to not damage the bearing, bearing cage or case.
5. 
To install: Ensure that the output housing bore is free of any dirt, burrs or nicks. Apply premium long-life grease
to the seal lip.
6. 
Position the new seal to the output housing and using an appropriate driver, such as the Output Shaft
Seal Replacer T83T-7065-B and Driver Handle T80T-4000-W, press the seal into the housing until
fully seated.
7. 
Install the rear out put shaft yoke, rubber seal and washer.
8. 
Install the output shaft yoke retaining nut and tighten to 250-280 ft. lbs. (339-381 Nm).
9. 
Connect the rear driveshaft to the transfer case.
10. 
Lower the vehicle.
11. 
Drive the vehicle and check for leaks.
12. 
Drive the new seal into the case housing using the appropriate seal installation tool Click to enlarge
Front Output Shaft Seal
REMOVAL & INSTALLATION
Borg Warner 13-54 and 1995-96 44-05 models HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 795 
						

							Cutaway view of the front output shaft , seal and yoke assembly-rear components are similar
Click to enlarge
Raise and safely support the vehicle.
1. 
If equipped, remove the skid plate from the frame.
2. 
If equipped, remove the damper from the transfer case.
3. 
Place a drain pan under the transfer case, remove the drain plug and drain the fluid.
4. 
Matchmark the front driveshaft to the transfer case yoke then disconnect the shaft from the yoke.
Wire the driveshaft up and out of the way.
5. 
Using a 30mm (1.18 in.) thin-wall socket, remove the rear output shaft yoke retaining nut.
6. 
Remove the output shaft yoke washer, rubber seal and the yoke from the output shaft.
7. 
Remove the front output shaft seal using Impact Slide Hammer Tool T50T-100-A or equivalent.
8. 
To install: Ensure that the output housing bore is free of any dirt, burrs or nicks. Apply premium long-life grease
to the seal lip.
9. 
Position the new seal to the output housing and using an appropriate driver, such as the Output Shaft
Seal Replacer T83T-7065-B and Driver Handle T80T-4000-W, press the seal into the housing until
fully seated.
10. 
Install the front output shaft yoke, rubber seal and washer.
11. 
Install the output shaft yoke retaining nut and tighten to 250-280 ft. lbs. (339-381 Nm).
12. 
Connect the front driveshaft to the transfer case.
13. 
If removed, install the damper.
14. 
Remove the oil fill plug and add the proper amount of Dexron/Mercon® automatic transmission fluid.
15. 
If removed, install the skid plate.
16. 
Lower the vehicle.
17. 
Drive the vehicle and check for leaks.
18.  HOW TO USE THIS BOOK
796 REMOVAL & INSTALLATION 
						

							
AWD and 1997-99 Borg Warner 44-05 Models
In order to replace the front output shaft seal on the AWD and 1997-99 Borg Warner 44-05 transfer cases,
they must be removed from the vehicle and their cases must be split. The output shaft is retained internally by
a snapring. Consult a professional repair shop as specialized knowledge of transfer cases is required.
Transfer Case Assembly
REMOVAL & INSTALLATION
Exploded view of the 13-54 mechanical shift transfer caseClick to enlarge
HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 797 
						

							Exploded view of the 13-54 electronic shift transfer case-44-05 model is similar
Click to enlarge
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.
Disconnect the negative battery cable.
1. 
Raise the vehicle and support it safely.
2. 
If so equipped, remove the skid plate from frame.
3. 
Remove the damper from the transfer case, if so equipped.
4. 
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.
5. 
Disconnect the front driveshaft from the axle input yoke.
6. 
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.
7. 
Disconnect the rear driveshaft from the transfer case output shaft yoke.
8. 
If equipped, disconnect the speedometer driven gear from the transfer case rear cover.
9. 
If equipped, disconnect the electrical wire harness plug from the Vehicle Speed Sensor (VSS).
10. 
Disconnect the vent hose from the mounting bracket.
11. 
On manual shift models, perform the following: Remove the shift lever retaining nut and remove the lever.
1. 
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.
2. 
12. 
If equipped, remove the heat shield from the transfer case.
13. 
Support the transfer case with a transmission jack.
14. 
Remove the 5 bolts (6 bolts on the AWD transfer case) retaining the transfer case to the transmission
and the extension housing.
15. 
Slide the transfer case rearward off the transmission output shaft and lower the transfer case from the
vehicle. Remove the gasket from between the transfer case and extension housing.
16. 
To install: HOW TO USE THIS BOOK
798 REMOVAL & INSTALLATION 
						

							Case-to-extension bolt torque sequence for all models except the AWD transfer case
Install the heat shield onto the transfer case, if equipped, and place a new gasket between the transfer
case and adapter.
17. 
Raise the transfer case with a suitable transmission jack or equivalent, raise it high enough so that the
transmission output shaft aligns with the splined transfer case input shaft.
18. 
Slide the transfer case forward on to the transmission output shaft and onto the dowel pin. Install
transfer case retaining bolts and torque them to specification.
19. 
The remainder of the installation procedure is the reverse of removal. Check the fluid level and, if
necessary, top off with Dexron/Mercon automatic transmission fluid to achieve the proper level.
20. 
ADJUSTMENTS
Manual Shift Models HOW TO USE THIS BOOK
ADJUSTMENTS 799 
						

							Exploded view of the manual shift transfer case controls
Click to enlarge
The following procedure should be used, if a partial or incomplete engagement of the transfer case shift lever
detent is experienced or if the control assembly requires removal.
Disconnect the negative battery cable.
1. 
Raise the shift boot to expose the top surface of the cam plates.
2. 
Loosen the 1 large and 1 small bolt, approximately 1 turn. Move the transfer case shift lever to the
4Lposition (lever down).
3. 
Move the cam plate rearward until the bottom chamfered corner of the neutral lug just contacts the
forward right edge of the shift lever.
4. 
Hold the cam plate in this position and torque the larger bolt first to 70-90 ft. lbs. (95-122 Nm) and
torque the smaller bolt to 31-42 ft. lbs. (42-57 Nm).
5. 
Move the transfer case in cab shift lever to all shift positions to check for positive engagement. There
should be a clearance between the shift lever and the cam plate in the 2Hfront and 4Hrear (clearance
not to exceed 3.3mm) and 4Lshift positions.
6. 
Install the shift boot assembly.
7. 
Reconnect the negative battery cable.
8. 
Except Manual Shift Models
Both of the electronic shift and the AWD model transfer cases do not require any linkage adjustments, nor are
any possible.
Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. HOW TO USE THIS BOOK
800 ADJUSTMENTS 
						

							
DRIVELINE
General Description
The driveshaft is a steel tubular or aluminum shaft which is used to transfer the torque from the engine,
through the transmission output shaft, to the differential in the axle, which in turn transmits torque to the
wheels.
The splined slip yoke and transmission output shaft permit the driveshaft to move forward and rearward as the
axle moves up and down. This provides smooth performance during vehicle operation.
The front driveshaft connects the power flow from the transfer case to the front drive axle.
Some vehicles may be equipped with a Double Cardan type driveshaft. This driveshaft incorporates 2
U-joints, a centering socket yoke and a center slip at the transfer case end of each shaft. A single U-joint is
used at the axle end of the shaft.
The Constant Velocity (CV) type U-joint allows the driveline angel to be adjusted according to the
up-and-down movement of the vehicle without disturbing the power flow. The CV U-joint is composed of
an outer bearing retainer and flange, spring, cap, circlip, inner bearing assembly and wire ring. The inner
bearing assembly is composed of a bearing cage, 6 ball bearings and an inner race.
The driveshafts used on Ranger, Explorer and Mountaineer may be 1 of 3 types. They are as follows: Front and rear driveshaft-Single Cardan type U-joint
· 
Front and rear driveshaft-Double Cardan type U-joint
· 
Rear driveshaft-CV (Constant Velocity) type U-joint
· 
Single Cardan Type Front Driveshaft
REMOVAL & INSTALLATION
DRIVELINE 801