Sunday, June 19, 2011

how to replace transfer case on 2006 ford escape?

Transfer Case Removal & Installation


With Automatic Transaxle



  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Disconnect the battery.
  3. Drain the transfer case.
  4. Remove the front right intermediate shaft.
  5. Remove the driveshaft.
  6. Remove the 4 bolts and the crossmember brace.
  7. Remove the generator.
  8. Remove the exhaust as required.
  9. Remove the heat shield.
  10. Remove the transfer case-to-transaxle bolts.
  11. Remove the transfer case.
    WARNING
    A new transfer case driven gear seal must be installed whenever the intermediate shaft or transfer case is removed from the vehicle.


    NOTE
    If necessary, replace the right differential fluid seal.

  12. To install, reverse the removal procedure. Observe the following torques:

    Crossmember bolts: 30 ft. lbs. (40 Nm).
    Transfer case-to-transaxle bolts: 33 ft. lbs. (45 Nm).

    image

    Fig. Transfer case mounting with automatic transaxle-



With Manual Transaxle



  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove the driveshaft.
  3. Remove the 4 bolts and the crossmember brace.
  4. Remove the transfer case-to-transaxle bolts.
  5. Remove the transfer case-to-transaxle nut.
  6. Remove the transfer case.
  7. To install, reverse the removal procedure.
    WARNING
    The O-ring must be properly installed before mating the transfer case to the manual transaxle. Failure to properly install the O-ring may cause the O-ring to be damaged resulting in transaxle oil leak.

  8. Install a new O-ring seal. Observe the following torques:

    Crossmember bolts: 30 ft. lbs. (40 Nm).
    Transfer case mounting nuts: 33 ft. lbs. (45 Nm).
    Transfer case mounting bolts: 33 ft. lbs. (45 Nm).

    image

    Fig. Transfer case mounting with manual transaxle-


-------------------

Removal & Installation

eCVT Transmission



  1. Before servicing the vehicle, refer to the Precautions Section.
    CAUTION
    Before proceeding, read and observe all of the High Voltage System Precautions.


    CAUTION
    To prevent exposure to high voltage, do not for any reason open the electronically controlled, continuously variable transaxle (eCVT) cover. Failure to follow these instructions may result in personal injury.


All vehicles

  1. With the vehicle in DRIVE, position it on a hoist.
  2. Release the fuel system pressure.
  3. Disconnect the battery ground cable.
    WARNING
    Before removing the high voltage cables, the vehicle electrical system must be completely shut down for at least 10 minutes to allow for the high voltage capacitors to discharge.

  4. Disarm the high voltage traction battery. Establish a buffer zone. See the procedure under Disarming the High Voltage Traction Battery.
  5. Drain the engine cooling system.
    WARNING
    The coolant must be recovered in a suitable, clean container for reuse. If the coolant is contaminated, it must be recycled or disposed of correctly.


    WARNING
    Always refill the motor electronics cooling system (MECS) with the same type of coolant that was drained from the system. Do not mix coolant types.

  6. Turn the ignition to the OFF position.
  7. Remove the left splash shield.
  8. Place a suitable container below the transaxle.
  9. Loosen the hose clamps at the transaxle, then pull the hoses off to allow the coolant to drain.
  10. Remove the upper and lower intake manifold.
  11. Remove the engine air cleaner.
  12. Remove the exhaust manifold/catalytic converter.
  13. Disconnect the motor electronics coolant vent hose.
  14. Disconnect the 2 engine coolant vent hoses.
  15. Remove the degas bottle bolt and nut.
  16. Lift the degas bottle up and disconnect the engine coolant and motor electronics coolant return hoses.
  17. Remove the degas bottle.
  18. Remove the accessory drive belt.
  19. Remove the left front drive halfshaft.

4WD vehicles

  1. Remove the transfer case.

2WD vehicles

  1. Remove the front drive intermediate halfshaft.
  2. Remove the bolts and the lateral support crossmember.

All vehicles

  1. Drain the engine oil.
  2. Disconnect the heater hoses from the heater core.
  3. Detach the heater hose retaining clip from the transaxle mount stud.
  4. Disconnect the upper radiator and coolant vent hoses.
  5. Disconnect the following electrical connectors:

    Secondary Air Injection (AIR) solenoid
    Transaxle mount control solenoid
    Purge valve

  6. Disconnect the engine control harness.
  7. Disconnect the 2 engine control harness electrical connectors and the 2 pin-type retainers.
  8. Remove the bolt and disconnect the transaxle harness electrical connector.
  9. Disconnect the DC-to-DC converter electrical connector and pin-type retainer.
  10. Disconnect and remove the fuel supply tube and evaporative emissions (EVAP) tube.
  11. If equipped, position the block heater wiring harness aside. Detach the 3 harness retainer clips. Route the harness through the radiator support into the engine compartment.
  12. Remove the 2 bolts and disconnect the auxiliary coolant pump electrical connector.
  13. Position the auxiliary coolant pump aside.
  14. Remove the bolts and the transaxle control splash shield.
  15. Disconnect the transaxle control cable.
  16. Disconnect the pin-type retainer.
  17. Disconnect the pin-type retainer and position the transaxle control cable aside.
  18. Disconnect the motor electronics coolant temperature sensor electrical connector and pin-type retainer.
  19. Disconnect the transaxle coolant hoses.
  20. Remove the nut and the ground cable.
  21. Remove the 2 bolts and position the motor electronics coolant pump aside.
  22. Disconnect the lower radiator hose from the radiator.
  23. Disconnect the A/C compressor electrical connector and remove the 3 bolts. Position the A/C compressor aside and support the compressor with a length of mechanic's wire.
  24. Remove the front roll restrictor bolt.
  25. Remove the rear roll restrictor bolt.
  26. Remove the nut, bolts and the engine support crossmember.
    NOTE
    The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.

  27. Remove the 2 transaxle-to-engine bolts.
    NOTE
    The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.

  28. Remove the 2 transaxle-to-engine bolts.
    NOTE
    Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the lift table.

  29. Using the special tools, secure the engine to the lift table.
  30. Remove the engine mount bracket bolt.
  31. Remove the nuts and the engine mount bracket.
  32. Remove the right transaxle mount bracket nut.
  33. Remove the bolts and the right transaxle mount bracket.
  34. Remove the bolts and the rear transaxle mount brace.
  35. Remove the nuts, bolt and rear transaxle mount.
  36. Lower the engine and transaxle from the vehicle.
  37. Using the engine crane and spreader bar, remove the engine and transaxle from the lift table.
  38. Disconnect the high voltage wiring harness electrical connector.
  39. Disconnect the 2 low voltage wiring harness electrical connectors and position the harness aside.
    NOTE
    The transaxle-to-engine bolts differ in length. Mark the bolts for correct installation.

  40. Remove the remaining 6 engine-to-transaxle bolts and separate the engine and transaxle.
    WARNING
    The damper contains a clutch which designed to slip briefly during vehicle operation. It is essential that no grease, oil or cleaning solvents be allowed to contaminate the slip clutch. Do not use grease on transaxle input shaft or input shaft splines.

  41. Should the damper become contaminated it must be replaced.
    NOTE
    Due to packaging requirements, the correct bolt must be used at the damper locations.

  42. Remove the bolts and the transaxle damper.

To install:


CAUTION
To prevent exposure to high voltage, do not for any reason open the electronically controlled, continuously variable transaxle (eCVT) cover. Failure to follow these instructions may result in personal injury.

All vehicles


WARNING
The damper contains a clutch which designed to slip briefly during vehicle operation. It is essential that no grease, oil or cleaning solvents be allowed to contaminate the slip clutch. Do not use grease on transaxle input shaft or input shaft splines.

  1. Should the damper become contaminated it must be replaced.
    NOTE
    Due to packaging requirements, the correct bolt must be used at the damper locations.

  2. Install the transaxle damper. Tighten to 21 ft. lbs. (29 Nm).
    WARNING
    When positioning the engine to the transaxle, care must be taken to maintain alignment of the damper spline with the transaxle input shaft.


    NOTE
    Transaxle removed from view for clarity.

  3. Using the engine crane and spreader bar, position the engine and transaxle together.
  4. Install the 6 transaxle-to-engine bolts. Tighten to 35 ft. lbs. (47 Nm).
  5. Position the low voltage wiring harness and connect the 2 transaxle electrical connectors.
  6. Connect the high voltage wiring harness electrical connector.
  7. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
    WARNING
    Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the lift table.

  8. Using the special tools, secure the engine to the lift table.
  9. Raise the engine and transaxle into the vehicle.
  10. Install the rear transaxle mount. Tighten to 66 ft. lbs. (90 Nm).
  11. Install the rear transaxle mount bracket. Tighten to 18 ft. lbs. (25 Nm).
  12. Install the right transaxle mount bracket. Tighten to 66 ft. lbs. (90 Nm).
  13. Install the right transaxle mount bracket nut. Tighten to 66 ft. lbs. (90 Nm).
  14. Install the engine mount bracket. Tighten to 66 ft. lbs. (90 Nm).
  15. Install the engine mount bracket bolt. Tighten to 66 ft. lbs. (90 Nm).
  16. Install the 2 transaxle-to-engine bolts. Tighten to 35 ft. lbs. (47 Nm).
  17. Install the 2 transaxle-to-engine bolts. Tighten to 35 ft. lbs. (47 Nm).
  18. Install the engine support crossmember nut and bolts. Tighten to 129 ft. lbs. (175 Nm).
  19. Install the rear roll restrictor bolt. Tighten to 66 ft. lbs. (90 Nm).
  20. Install the front roll restrictor bolt. Tighten to 85 ft. lbs. (115 Nm).
  21. Install the A/C compressor and connect the A/C compressor electrical connector. Tighten to 18 ft. lbs. (25 Nm).
  22. Connect the lower radiator hose to the radiator.
  23. Install the motor electronics coolant pump. Tighten to 18 ft. lbs. (25 Nm).
  24. Install the ground cable and nut. Tighten to 15 ft. lbs. (20 Nm).
  25. Connect the transaxle coolant hoses.
  26. Connect the motor electronics coolant temperature sensor electrical connector and pin-type retainer.
  27. Position the transaxle control cable and connect the pin-type retainer.
  28. Connect the pin-type retainer.
  29. Connect the transaxle control cable. Install the transaxle control cable bracket and the 2 nuts finger tight. Attach the transaxle control cable to the control lever. Tighten to 16 ft. lbs. (22 Nm).
  30. Position the control lever between the 2 casting ribs on the transaxle case.
  31. Place the selector lever in the D position.
  32. Tighten the transaxle control cable bracket nuts to 16 ft. lbs. (22 Nm).
  33. To verify the correct cable adjustment, observe the control lever on the transaxle while an assistant shifts the selector lever to each range position ending in the D position.
  34. Install the transaxle control splash shield. Tighten to 11 ft. lbs. (15 Nm).
  35. Install the motor auxiliary coolant pump and connect the electrical connector. Tighten to 89 inch lbs. (10 Nm).
    NOTE
    Parts removed from view for clarity.

  36. If equipped, install the block heater wiring harness. Route the harness through the radiator support. Attach the 3 harness retainer clips.
  37. Install the fuel supply tube and evaporative emissions (EVAP) tube.
  38. Connect the DC-to-DC converter electrical connector and pin-type retainer.
  39. Connect the transaxle harness electrical connector and install the bolt. Tighten to 18 ft. lbs. (25 Nm).
  40. Connect the 2 engine control harness electrical connectors and the 2 pin-type retainers.
  41. Connect the engine control harness. Engage the Powertrain Control Module (PCM) connector. Install the harness retaining nut. Tighten to 53 inch lbs. (6 Nm).
  42. Connect the following electrical connectors:

    Secondary Air Injection (AIR) solenoid
    Transaxle mount control solenoid
    Purge valve

  43. Connect the upper radiator and coolant vent hoses.
  44. Attach the heater hose retaining clip to the transaxle mount stud.
  45. Connect the heater hoses to the heater core.

2WD vehicles

  1. Install the lateral support crossmember. Tighten to 85 ft. lbs. (115 Nm).
  2. Install the front drive intermediate halfshaft.

4WD vehicles

  1. Install the transfer case.

All vehicles

  1. Install the left front drive halfshaft.
  2. Install the accessory drive belt.
  3. Install the engine coolant degas bottle.
  4. Install the exhaust manifold/catalytic converter.
  5. Install the engine air cleaner.
  6. Install the intake manifold.
  7. Enable the vehicle high voltage electrical system. See the procedure under High Voltage Traction Battery.
  8. Connect the battery ground cable.
  9. Fill the engine with clean engine oil.
  10. Connect the hoses to the transaxle and install the hose clamps.
    WARNING
    Adhesives, stop-leak pellets or small debris in the Motor electronics cooling system (MECS) can cause poor performance or temporary blockage of the motor electronics pump. Only use clean, approved coolant when filling the system.

  11. Loosen the bleed screw and fill the degas bottle with coolant until it begins to flow out of the bleed hole. Then, close the bleed screw.
  12. Turn the ignition to the ON position to actuate the motor electronics cooling pump and continue to fill the degas bottle to the correct level.
    NOTE
    Most of the MECS air bleeding occurs as a normal process at the degas bottle through the vent tube; very little occurs at the bleed screw.

  13. To bleed air from the system, loosen the bleed screw and allow air to escape while the M/E coolant pump is operating. Fill and bleed the motor electronics cooling system.
  14. Fill and bleed the engine cooling system.

Lower Insulator & Retainer



  1. Before servicing the vehicle, refer to the Precautions Section.
  2. With the vehicle in DRIVE, position it on a hoist.
  3. Turn the ignition to the OFF position.
  4. Remove the splash shield retainers and remove the left splash shield.
  5. Remove the bolts and the lateral support crossmember.
  6. Remove the front insulator bolt.
  7. Remove the rear insulator bolt.
  8. Remove the nut, bolts and the crossmember.
  9. Remove the lower rear insulator bolt and remove it from the bracket.
  10. To install, reverse the removal procedure. Observe the following torques:

    Lower rear insulator bolt: 66 ft. lbs. (90 Nm)
    Crossmember front bolts: 66 ft. lbs. (90 Nm)
    Crossmember rear nut: 111 ft. lbs. (150 Nm)
    Front and rear insulator bolts: 66 ft. lbs. (90 Nm)
    Lateral support crossmember bolts: 85 ft. lbs. (115 Nm)


Motor Electronics Cooler



  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    Always refill the motor electronics cooling system (MECS) with the same type of coolant that was drained from the system. Do not mix coolant types.

  2. With the vehicle in DRIVE, position it on a hoist.
  3. Turn the ignition to the OFF position.
  4. Remove the left splash shield.
  5. Place a suitable container below the transaxle.
  6. Loosen the hose clamps at the transaxle, then, pull the hoses off to allow the coolant to drain.
  7. Remove the front bumper cover.
    1. Remove the 6 pin-type retainers (3 each side).
    2. Remove the 4 fender splash shield bolts (2 each side).
    3. Remove the 4 air deflector bolts.
    4. Remove the 2 center front bumper cover pin-type retainers.
    5. Remove the 2 front bumper cover outer pin-type retainers (1 each side).
    6. If equipped, disconnect the fog lamp electrical connectors.
    7. Remove the 2 upper bolts and the front bumper cover.

  8. Loosen the hose clamp and disconnect the inlet hose.
  9. Loosen the hose clamp and disconnect the outlet hose.
  10. Remove the motor electronics (M/E) cooler bolts.
  11. To install, reverse the removal procedure. Observe the following torques:

    Motor electronics (M/E) cooler bolts: 53 inch lbs. (6 Nm)
    Front bumper cover bolts: 71 inch lbs. (8 Nm)
    Air deflector bolts: 71 inch lbs. (8 Nm)
    Fender splash shield bolts: 71 inch lbs. (8 Nm)

    Click image to see an enlarged view

    Fig. Motor electronics cooling system-Escape Hybrid



    Click image to see an enlarged view

    Fig. Motor electronics cooler hose connections-Escape Hybrid


  12. Connect the hoses to the transaxle and install the hose clamps.
    WARNING
    Adhesives, stop-leak pellets or small debris in the Motor electronics cooling system (MECS) can cause poor performance or temporary blockage of the motor electronics pump. Only use clean, approved coolant when filling the system.

  13. Loosen the bleed screw and fill the degas bottle with coolant until it begins to flow out of the bleed hole. Then, close the bleed screw.
  14. Turn the ignition to the ON position to actuate the motor electronics cooling pump and continue to fill the degas bottle to the correct level.
    NOTE
    Most of the MECS air bleeding occurs as a normal process at the degas bottle through the vent tube; very little occurs at the bleed screw.

  15. To bleed air from the system, loosen the bleed screw and allow air to escape while the M/E coolant pump is operating.

Motor Electronics Pump



  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    Always refill the motor electronics cooling system (MECS) with the same type of coolant that was drained from the system. Do not mix coolant types.

  2. With the vehicle in DRIVE, position it on a hoist.
  3. Turn the ignition to the OFF position.
  4. Remove the left splash shield.
  5. Place a suitable container below the transaxle.
  6. Disconnect the inlet and outlet hoses.
  7. Remove the bolts.
  8. To install, reverse the removal procedure. Tighten to 15 ft. lbs. (20 Nm).
    WARNING
    Adhesives, stop-leak pellets or small debris in the Motor electronics cooling system (MECS) can cause poor performance or temporary blockage of the motor electronics pump. Only use clean, approved coolant when filling the system.

  9. Loosen the bleed screw and fill the degas bottle with coolant until it begins to flow out of the bleed hole. Then, close the bleed screw.
  10. Turn the ignition to the ON position to actuate the motor electronics cooling pump and continue to fill the degas bottle to the correct level.
    NOTE
    Most of the MECS air bleeding occurs as a normal process at the degas bottle through the vent tube; very little occurs at the bleed screw.

  11. To bleed air from the system, loosen the bleed screw and allow air to escape while the M/E coolant pump is operating.

Rear Insulator & Retainer



  1. Before servicing the vehicle, refer to the Precautions Section.
  2. With the vehicle in DRIVE, position it on a hoist.
  3. Turn the ignition to the OFF position.
  4. Disconnect the heater hose retaining clip from the transaxle mount stud.
  5. Remove insulator nut.
  6. Remove the nuts and the bracket.
  7. Remove the nuts, heat shield, and insulator.
  8. To install, reverse the removal procedure. Tighten all fasteners to 66 ft. lbs. (90 Nm).

Upper Insulator & Retainer



  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove the air cleaner assembly.
  3. Support the transaxle with a suitable floor jack.
  4. Remove the bolts and the bracket.
  5. Remove the nuts, bolt and the insulator.
  6. To install, reverse the removal procedure. Torque the insulator bracket bolts to 18 ft. lbs. (25 Nm); the insulator bolts/nuts to 66 ft. lbs. (90 Nm).

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