The Ford Explorer, Mercury Mountaineer Repair Manual 2002-2010 by Chilton covers U.S. and Canadian SUV models powered by V6 and V8 engines, with manual and automatic transmissions. Note: this manual DOES NOT include information on Sport Trac models.
Book Excerpt: 2002-2010 Ford Explorer, Mercury Mountaineer Repair Manual COOLING, HEATING AND AIR CONDITIONING SYSTEMS

WATER PUMP | REPLACEMENT
(Refer to illustration 8.5)

1. Disconnect the cable from the negative battery terminal (see Chapter 5).
2. Drain the cooling system (see Chapter 1).
3. Remove the drivebelt (see Chapter 1).
4. Remove the engine cooling fan (see Section 4).
5. Remove the water pump pulley (see illustration). When loosening the bolts, hold the pulley with a strap or chain wrench to prevent it from turning.
V6 MODELS
(Refer to illustration 8.6 and 8.7)
6. Remove the bypass hose, the heater hose and the lower radiator hose from the water pump (see illustration).
7. Remove the bolts attaching the water pump to the engine block and remove the pump from the engine (see illustration). If the water pump is stuck, gently tap it with a soft-faced hammer to break the seal.
8. Clean the bolt threads and the threaded holes in the engine and remove the corrosion and sealant. Remove all traces of old gasket material from the sealing surfaces.
V8 MODELS
(Refer to illustrations 8.9, 8.10 and 8.11)
9. Remove the water pump mounting bolts (see illustration).
10. Clean the O-ring surfaces on the pump and the housing (see illustration).
11. If you're installing the old pump, install a new O-ring (see illustration).
12. Clean the bolt threads and the threaded holes in the engine and remove the corrosion and debris.

TRANSFER CASE

TRANSFER CASE | REMOVAL AND INSTALLATION

1. Raise the vehicle and support it securely on jackstands.
2. Remove the front drive shaft and the rear drive shaft from the transfer case (see Chapter 8). Always remove the drive shaft from the transfer case first to prevent the boot from tearing in the event the driveshaft drops to a lower angle. Remove the skidplate, if equipped.
3. Drain the transfer case fluid if the transfer case will be repaired (see Chapter 1).
4. On A4WD models, disconnect the electronic shift motor connector (see Section 3).
5. Disconnect the vent hose.
6. Place a floor jack under the transmission. Place a wood block between the jack head and the transmission to protect the case.
7. Place a transmission jack under the transfer case and secure the transfer case to the jack with safety chains or straps.

Subject: 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Ford Explorer, Mercury Mountaineer service, maintenance, repair. ISBN-10: 1563928361 | ISBN-13: 9781563928369 | Chilton 26280