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scottz136, Mercury Technician
Category: Mercury
Satisfied Customers: 1940
Experience:  senior master lincoln mercury tech.
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I have a 2003 Mercury Mountaineer AWD . For some reason it

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I have a 2003 Mercury Mountaineer AWD . For some reason it has locked into full time four wheel drive and wont disengage ? Is there a sensor that is making this happen ? It hops very bad when in a tight turn just like a four wheel drive with the front hubs locked in ? HELP ?
HiCustomer Thank you for asking your question on JustAnswer. The other Experts and I are working on your answer. By the way, it would help us to know:
-Is you 4x4 lamp on?

Thank you again for trusting us with your problem. Please reply as soon as possible so that we can finish answering your question.
Customer: replied 7 years ago.

no but the abs lamp has come on for some reason


Customer: replied 7 years ago.

you still online with me ?


Does the 4wd lamp come on when you select 4wd?
Customer: replied 7 years ago.
Its an AWD ...notXXXXX. I have no way of selecting 4 orXXXXXin this vehicle .
Ok, then the only possible cause of this is an internal failure of the transfer case.Here is a pinpoint chart from the ford service manual that shows that the transfer case wil need disassembling to inspect the planetary gears,bearings,and drive system.
  • Wheel/tire bounce, vehicle skip
  • Internal components.
  • OPERATE the vehicle in all transmission gears. If there is noise in the transmission in NEUTRAL, or in some gears and not in others, REMOVE and REPAIR the transmission. REFER to Section 307-01. If there is noise in all gears, DISASSEMBLE the transfer case. REFER to Transfer Case — All Wheel Drive (AWD) in this section. CHECK the planetary gears, the bearings, the upper and lower drive sprockets and drive chain for damage. INSTALL new parts as necessary.
  • Tire tread wear.
  • MAKE SURE that all tires and wheels are the same size and that inflation pressures are correct. REFER to Section 204-00.


Item Part Number Description
1 7045 Output flange nut
Disassembly Note
Assembly Note
2 7B368 Output shaft yoke washer
3 7B214 Output flange
4 7052 Oil seal
5 7A443 Bolt (17 req'd)
6 7005 Case
Disassembly Note
Assembly Note
7 7A153 Upper output shaft and ring gear
Disassembly Note
Assembly Note
8 7917 Snap ring
9 7025 Bearing
10 7B215 Yoke to flange seal
Assembly Note
11 7C122 Snap ring
12 7061 Upper output shaft
13 7L290 Oil scoop
14 7R141 Snap ring
15 7025 Bearing
Disassembly Note
16 7A771 Torx® head screw (4 req'd)
17 7F123 Damper snubber
18 7A385 Output shaft thrust washer
19 7A398 Front planetary gear assembly
20 7A385 Thrust washer
21 7177 Upper drive sprocket
Disassembly Note
22 7D063 Overdrive sun gear
23 7A029 Drive chain
24 7177 Lower drive sprocket
Assembly Note
25 7A385 Thrust washer
26 7L499 Coupling (viscous)
27 7017 Input shaft assembly
28 7025 Bearing
Disassembly Note
Assembly Note
29 7917 Snap ring
Disassembly Note
30 7061 Output shaft
31 7C016 Dust deflector
32 7025 Bearing
Disassembly Note
Assembly Note
33 7B215 Yoke to flange seal
Assembly Note
34 7B215 Input shaft seal
35 7025 Bearing
Customer: replied 7 years ago.
OK , If I remove either the front or rear drive shaft due to the locking up into four wheel drive , would it hurt the transfer case if i drove it that way until i can put it in the shop for repairs ?
Yes you can remove the front driveshaft and it will drive fine. It wont damage transfer case ,which is already damaged.
scottz136, Mercury Technician
Category: Mercury
Satisfied Customers: 1940
Experience: senior master lincoln mercury tech.
scottz136 and 2 other Mercury Specialists are ready to help you

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