Section 308-07B: Transfer Case � Control Trac 1997 Explorer Workshop ManualIN-VEHICLE REPAIR

Switch, Shift Range Selector

Removal

Remove and reposition the center instrument panel finish panel (044D70).Remove the screws.1. Remove and reposition the instrument panel finish panel.2.

1.

Disconnect the electrical connectors.Disconnect the shift range selector switch electrical connector.1. Disconnect the cigar lighter electrical connectors.2.

2.

Disconnect the electrical connectors.Disconnect the rear heated back light switch electrical connector.1. Disconnect the rear wiper switch electrical connector (if equipped).2.

3.

Disconnect the radio electrical connector.4.

1997 Explorer/Mountaineer

Switch, Shift Range Selector 2999

Remove the instrument panel finish panel.5.

Remove the shift range selector switch knob.6.

Remove the shift range selector.Remove the screws.1. Remove the switch.2.

7.

Installation

To install, reverse the removal procedures.1.

1997 Explorer/Mountaineer

Switch, Shift Range Selector 3000

1997 Explorer/Mountaineer

Switch, Shift Range Selector 3001

Section 308-07B: Transfer Case � Control Trac 1997 Explorer Workshop ManualIN-VEHICLE REPAIR

Motor, Electric Shift

Removal

WARNING: THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEMMUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSIONVEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCHLOCATED IN THE REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT INUNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT INSHIFTING OF THE VEHICLE DURING THESE OPERATIONS.

Raise and support the vehicle. Refer to Section 100-02 .1.

Disconnect the electrical shift motor connector.2.

Remove the coil wire from the electrical shift motor electrical connector.Remove the wire connector spacer.1. Remove the coil wire and pin.2. Use the proper electrical connector pin remover.•

3.

Remove the electric shift motor.Remove the four electric shift motor bolts.1. Remove the electric shift motor.2.

4.

1997 Explorer/Mountaineer

Motor, Electric Shift 3002

Installation

NOTE: If equipped with air suspension, reactivate the system by turning on the air suspensionswitch.

To install, reverse the removal procedure.

1.

1997 Explorer/Mountaineer

Motor, Electric Shift 3003

Section 308-07B: Transfer Case � Control Trac 1997 Explorer Workshop ManualIN-VEHICLE REPAIR

Seal, Oil � Rear

Special Service Tool(s)

Impact Slide Hammer or equivalentD80L-100-D

Seal RemoverT77F-1102-A

Seal ReplacerT96T-7127-A

Removal

WARNING: THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEMMUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSIONVEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCHLOCATED IN THE REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT INUNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT INSHIFTING OF THE VEHICLE DURING THESE OPERATIONS.

With the vehicle in neutral, raise and support the vehicle; refer to Section 100-02 .1.

Index the rear driveshaft yoke to the transfer case companion flange.2.

Index the rear driveshaft to driveshaft rear axle companion flange.3.

1997 Explorer/Mountaineer

Seal, Oil � Rear 3004

Remove the four rear bolts and disconnect the rear driveshaft.4.

Separate the rear driveshaft from the transfer case.Remove the four bolts.1. Carefully remove the driveshaft.2.

5.

Mark the rear transfer case flange and the rear output shaft for proper assembly.6.

Remove the rear transfer case flange.Remove the nut.1. Remove the washer.2. Remove the seal.3. Remove the rear transfer case flange.4.

7.

1997 Explorer/Mountaineer

Seal, Oil � Rear 3005

Use Seal Remover and Impact Slide Hammer to remove the rear transfer case flange seal.8.

Installation

Use Seal Replacer and install the rear transfer case flange seal.1.

Align marks on the transfer case flange and the rear output shaft.2.

Position the rear transfer case flange.Position the rear output flange.1. Position the seal.2. Position the washer.3. Position the nut.4.

3.

1997 Explorer/Mountaineer

Seal, Oil � Rear 3006

Using Companion Flange Holding Tool, tighten the rear output flange nut.4.

Align marks on the driveshaft to driveshaft rear axle companion flange and install bolts.5.

Align marks on driveshaft yoke and transfer case companion flange and install the driveshaft bolts.6.

NOTE: If equipped with air suspension, reactivate the system by turning on the air suspensionswitch.

Lower the vehicle.

7.

1997 Explorer/Mountaineer

Seal, Oil � Rear 3007

1997 Explorer/Mountaineer

Seal, Oil � Rear 3008

Section 308-07B: Transfer Case � Control Trac 1997 Explorer Workshop ManualIN-VEHICLE REPAIR

Vehicle Speed Sensor (VSS)

Removal

WARNING: THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEMMUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSIONVEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCHLOCATED IN THE REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT INUNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT INSHIFTING OF THE VEHICLE DURING THESE OPERATIONS.

Raise and support vehicle. Refer to Section 100-02 .1.

Remove the vehicle speed sensor (VSS).Remove the VSS electrical connector.1. Remove the VSS nut.2. Remove the VSS.3.

2.

Remove the VSS gear.3.

1997 Explorer/Mountaineer

Vehicle Speed Sensor (VSS) 3009

Installation

Install the VSS gear.1.

NOTE: Lubricate the VSS O-ring with Motorcraft MERCON® Multi-Purpose Automatic Transmission FluidXT-2-BDX-DDX, -QDX or equivalent.

Install the VSS.Position the VSS.1. Install the nut.2. Install the electrical connector.3.

2.

1997 Explorer/Mountaineer

Vehicle Speed Sensor (VSS) 3010

NOTE: If equipped with air suspension, reactivate the system by turning on the air suspensionswitch.

Lower the vehicle.

3.

1997 Explorer/Mountaineer

Vehicle Speed Sensor (VSS) 3011

Section 308-07B: Transfer Case � Control Trac 1997 Explorer Workshop ManualIN-VEHICLE REPAIR

Gear, Speedometer Drive

Removal

WARNING: THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSIONSYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIRSUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIRSUSPENSION SWITCH LOCATED IN THE REAR JACK STORAGE AREA. FAILURE TODO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIRSPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESEOPERATIONS.

With the vehicle in neutral, raise and support the vehicle; refer to Section 100-02 .

1.

Remove the vehicle speed sensor (VSS).Remove the electrical connector.1. Remove the nut.2. Remove the VSS.3.

2.

Index the rear driveshaft yoke to transfer case companion flange.3.

Separate the rear driveshaft from the transfer case.Remove the four bolts.1. Carefully remove the driveshaft.2.

4.

1997 Explorer/Mountaineer

Gear, Speedometer Drive 3012

Mark the rear transfer case flange and rear output shaft for proper assembly.5.

Using Companion Flange Holding Tool, loosen the rear output flange nut.6.

Remove the rear transfer case flange.Remove the nut.1. Remove the washer.2. Remove the seal.3. Remove the rear transfer case flange.4.

7.

Use the Seal Remover and remove the rear transfer case flange seal.8.

1997 Explorer/Mountaineer

Gear, Speedometer Drive 3013

Remove the speedometer drive gear.9.

Installation

NOTE: Inspect the tone wheel.

Install the speedometer drive gear.

1.

Use Seal Replacer and install the rear transfer case flange seal.2.

Align marks on the transfer case flange and rear output shaft.3.

Postion the rear transfer case flange.Position the output flange.1. Position the seal.2.

4.

1997 Explorer/Mountaineer

Gear, Speedometer Drive 3014

Position the washer.3. Position the nut.4.

Use Companion Flange Holding Tool, and tighten the rear output flange nut.5.

Align the marks on the rear driveshaft yoke and the transfer case companion flange and install thedriveshaft bolts.

6.

NOTE: Lubricate the VSS O-ring with Motorcraft MERCON® Multi-Purpose AutomaticTransmission Fluid XT-2-BDX, -DDX, -QDX or equivalent.

Install the VSS.

Position the VSS.1. Install the nut.2. Install the electrical connector.3.

7.

1997 Explorer/Mountaineer

Gear, Speedometer Drive 3015

Install the rear transfer case flange and seal; refer to the procedure in this section.8.

1997 Explorer/Mountaineer

Gear, Speedometer Drive 3016

Section 308-07B: Transfer Case � Control Trac 1997 Explorer Workshop ManualIN-VEHICLE REPAIR

Sensor, Output Shaft Speed � Front

Removal

Remove the electric shift motor, refer to the procedure in this section.1.

Remove the front output shaft speed sensor.Remove the bolt.1. Remove the front output shaft speed sensor.2.

2.

Remove the front output shaft speed sensor wires from the electrical shift motor connector.Use the proper electrical connector pin remover.•

3.

Installation

Install the front output shaft speed sensor.Position the front output shaft speed sensor.1. Install the bolt.2.

1.

1997 Explorer/Mountaineer

Sensor, Output Shaft Speed � Front 3017

Install the front output shaft speed sensor wires into the electrical shift motor connector.2.

Install the electrical shift motor; refer to the procedure in this section.3.

1997 Explorer/Mountaineer

Sensor, Output Shaft Speed � Front 3018

Section 308-07B: Transfer Case � Control Trac 1997 Explorer Workshop ManualIN-VEHICLE REPAIR

Sensor, Output Shaft Speed � Rear

Removal

WARNING: THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEMMUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSIONVEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCHLOCATED IN THE REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT INUNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT INSHIFTING OF THE VEHICLE DURING THESE OPERATIONS.

Raise and support vehicle. Refer to Section 100-02 .1.

Disconnect the shift motor electrical connector.2.

Remove the output shaft speed sensor wires from the electrical shift motor connector.Remove the wire connector spacer.1. Remove the wires.2. Use the proper electrical connector pin remover.•

3.

Remove the rear output shaft speed sensor bolt and remove sensor.4.

1997 Explorer/Mountaineer

Sensor, Output Shaft Speed � Rear 3019

Installation

Install the rear output shaft speed sensor and install the bolt.1.

Install the rear output shaft speed sensor wires into the electrical shift motor connector.2.

Reconnect the shift motor connector.3.

NOTE: If equipped with air suspension, reactivate the system by turning on the air suspensionswitch.

Lower the vehicle.

4.

1997 Explorer/Mountaineer

Sensor, Output Shaft Speed � Rear 3020

1997 Explorer/Mountaineer

Sensor, Output Shaft Speed � Rear 3021

Section 308-07B: Transfer Case � Control Trac 1997 Explorer Workshop ManualIN-VEHICLE REPAIR

Damper, Transfer Case Vibration

Removal

WARNING: THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEMMUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSIONVEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCHLOCATED IN THE REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT INUNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT INSHIFTING OF THE VEHICLE DURING THESE OPERATIONS.

Raise and support the vehicle. Refer to Section 100-02 .1.

Remove the transfer case vibration damper.Remove the nuts.1. Remove the transfer case vibration damper.2.

2.

Installation

NOTE: If equipped with air suspension, reactivate the system by turning on the air suspensionswitch, once the vehicle is lowered.

Position the vibration damper and install the bolts.

1.

1997 Explorer/Mountaineer

Damper, Transfer Case Vibration 3022