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Mercury Mountaineer 2003 Transfer Case Problem

February 3, 2014 - Author: BartBarton

Mercury Mountaineer 2003 Transfer Case Is Viscous Coupler Problem?

I have a Mercury Mountaineer 2003 with the 4.6L engine with automatic transmission and 4WD.


This vehicle has 125000 miles and has been used to pull a 25′ trailer over bw4410the last 5 summers.  When turning the vehicle on the asphalt it feels like the front tires are pawing, at first I thought that maybe it was the rear differential.  A few days ago it was stuck in the snow and the rear end was not locked up.  I have inspected both the front and rear differential with the covers off and all looks good.  I suspect the viscous clutch is the issue.


You have the BW4410 transfer case we agree based on your description the viscous coupler is defective and needs to be replaced.  While you have the unit apart we suggest you check the drive chain for excessive wear or stretch.  The parts you will need are:

  • Viscous Coupler part number MWT4400-625-001 your cost is $329.00
  • Seal kit your cost $15.00 plus S&H.

Make sure all of the tires are the same diameter and pressure, this is the #1 cause of viscous coupler failure.

For information on replacement transfer cases see our site.

10 Comments - Categories: Uncategorized

Transfer Case Maintenance and Service

- Author: BartBarton

Extend Life of Transfer Case with Maintenance and Service

Draining Fluid and replacing bw4407with fresh fluid really is a requirement and will add extra life to an expensive part. Over time additives within the fluid breakdown along with parts and component protections stops, small pieces of metallic and plastic wear away. Under some conditions i.e. bad weather, launching boats makes it possible for water to seep in to the unit. A very hot transfer case in chilly water can drawing in water thru seeping seals, contaminating the fluid and damaging shafts and bearings.

Fluid cools down the transfer case and it is components and lubricates gears, chain, shafts and bearings along with other parts. The transfer case does not have a filter and fluid needs to be change under normal use every 12 month generally, under intense use every 3 month, or in accordance using the manufactures owner’s handbook. Typical transfer cases hold in between 1.5 and 3 quarts of lubricant, check owner’s manual. We typically suggest automatic transmission fluid as lubricant but in a few case specialty dealer specific fluid is necessary, you should consult your owner’s manual. Or give us a call and take advantage of our experience and expertise.

One of the biggest problems with internal part damaged to transfer cases is started by uneven tire wear, or in most cases simply by used car dealers installing un-matched sets of tires. Be sure that you measure the OD tire dimension in  order to guarantee that they’re the same dimension.

For a detailed listing of replacement re-manufactured transfer cases see our web site. Our re-manufactured units have a 1 year unlimited mileage in 12 months warranty.


No Comments - Categories: Transfer Case