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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1546 (Transfer Case - Four Wheel Drive (4WD) Systems -- F250-F550 Super Duty) >> Diagnosis And Testing >> Four Wheel Drive (4WD) Systems - Mechanical Shift >> Pinpoint Tests >> Pinpoint Test D: The 4x4 System Jumps Out Of Gear >> Pinpoint Test D: The 4X4 System Jumps Out Of Gear

Pinpoint Test D: The 4X4 System Jumps Out Of Gear

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. D1 CHECK THE TRANSFER CASE SHIFT LEVER DETENT 
    • Inspect the transfer case shift lever assembly and detent for damage.
    • Are the components damaged? 

    Yes  : REPAIR or INSTALL new component(s) as necessary. TEST the vehicle for normal operation.

    No  : GO to D2.

  2. D2 CHECK THE SHIFT LEVER ASSEMBLY-TO-TRANSMISSION BOLT TORQUE 
    • Using a torque wrench, check the shift lever assembly-to-transmission bolt torque.
    • Is the bolt torque approximately 117 Nm (86 lb-ft) ± 9 Nm (80 lb-in)? 

    Yes  : GO to  D5.

    No  : GO to D3.

  3. D3 CHECK THE SHIFT LEVER RESIDUAL TORQUE 
    • Tighten the shift lever assembly-to-transmission bolt 117 Nm (86 lb-ft).
    • Cycle the shift lever several times.
    • Using a torque wrench, check the shift lever assembly-to-transmission bolt torque.
    • Is the bolt torque greater than 108 Nm (80 lb-ft)? 

    Yes  : GO to D4.

    No  : INSTALL a new transfer case shift lever assembly and/or shift lever assembly-to-transmission bolt. REFER to TRANSFER CASE . TEST the system for normal operation.

  4. D4 VERIFY IF THE CONCERN IS STILL PRESENT 
    • Drive the vehicle to verify if the 4x4 system jumps out of gear (attempt to duplicate the customer's concern).
    • Is the concern still present? 

    Yes  : GO to D5.

    No  : Return the vehicle to the customer. The problem may have been caused by incorrect shift lever bolt torque.

  5. D5 CHECK THE TRANSFER CASE MODE (4H OR 4L) WHERE THE CONCERN IS PRESENT 
    • Disconnect the transfer case shift lever from the transfer case.
    • Shift the transfer case into the suspect mode (4H or 4L), using a suitable wrench.
    • Drive the vehicle to verify if the 4x4 system jumps out of gear (attempt to duplicate the customer's concern).
    • Is the concern still present? 

    Yes  : GO to PINPOINT TEST C . CHECK specifically for MSOS mode indication switch and/or associated wiring problems. If no faults are found, REPAIR the transfer case.

    No  : GO to D6.

  6. D6 CHECK FOR SHIFT LEVER INTERFERENCE 
    • Check for interference between the shift lever and the inner boot, the console and floor pan while shifting through each lever position.
    • Is there interference between the shift lever and any of these components? 

    Yes  : CHECK the motor mounts and the transmission mount. REPAIR or INSTALL new components as necessary to eliminate the interferences. TEST the system for normal operation.

    No  : INSTALL a new transfer case shift lever assembly. REFER to TRANSFER CASE . TEST the system for normal operation.

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