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...

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...

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...

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...

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...

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...

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...

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...

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...