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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1810 (Transfer Case - Four Wheel Drive (4WD) Systems - F-150 & Mark LT) >> Diagnostic Tests >> Four Wheel Drive (4WD) Systems - Mechanical Shift >> Pinpoint Tests >> Pinpoint Test F: The Four Wheel Drive (4WD) System Jumps Out of Gear >> Pinpoint Test F: The 4WD System Jumps Out Of Gear

Pinpoint Test F: The 4WD System Jumps Out Of Gear

WARNING: This page is about a different car, the 2007 Lincoln Mark LT and 2007 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
  1. F1 CHECK THE TRANSFER CASE SHIFT LEVER DETENT 
    • Inspect the transfer case shift lever assembly and detent for damage.
    • Are the components damaged? 
    1. YES  : REPAIR or INSTALL new component(s) as necessary. TEST the vehicle for normal operation.
    2. NO  : Go to  F2.
  2. F2 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 N.m (86 lb-ft) ± 9 N.m (80 lb-in)? 
    1. YES  : Go to  F5.
    2. NO  : Go to  F3.
  3. F3 CHECK THE SHIFT LEVER RESIDUAL TORQUE 
    • Tighten the shift lever assembly-to-transmission bolt to 117 N.m (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 N.m (80 lb-ft)? 
    1. YES  : Go to  F4.
    2. NO  : INSTALL a new transfer case shift lever assembly and/or shift lever assembly-to-transmission bolt. REFER to TRANSFER CASE article. TEST the system for normal operation.
  4. F4 VERIFY THAT THE CONCERN IS STILL PRESENT 
    • Connect the diagnostic tool.
    • Monitor the MSS PIDs.
    • Drive the vehicle to verify if the four wheel drive (4WD) system jumps out of gear (attempt to duplicate the customer's concern).
    • Is the concern still present? 
    1. YES  : Go to  F5.
    2. NO  : CARRY OUT the Mechanical Shift on the Fly (MSOF) Functional Test. Go to Pinpoint Test H .
  5. F5 ATTEMPT TO DUPLICATE THE CONCERN 
    • Determine whether the transfer case pops in/out of gear intermittently (possibly over bumps) or if the concern is related to high torque maneuvers.
    • Determine if the 4WD indicators and MSOF position PIDs change when the concern is present.
    • Does the concern occur intermittently and is it accompanied by an indicator/position PID change? 
    1. YES  : Go to  F6.
    2. NO  : Go to  F7.
  6. F6 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 the transfer case external control lever.
    • Drive the vehicle to verify if the 4WD system jumps out of gear (attempt to duplicate the customer's concern).
    • Is the concern still present? 
    1. YES  : Go to Pinpoint Test C . CHECK specifically for intermittent mode indication switch (MIS) and/or associated wiring problems.
    2. NO  : Go to  F9.
  7. F7 CHECK THE IWE VENT LINES 
    • Disconnect the LH IWE lines from the vent ports. The IWE vent port is the smaller of the 2 vacuum ports.
    • Attach a vacuum pump to the IWE vent line.
    • Attempt to draw and hold a vacuum.
    • Repeat the previous steps for the RH side of the vehicle.
    • Were the vent lines obstructed (can a vacuum be held)? 
    1. YES  : INSTALL new IWE vent lines as necessary. TEST the system for normal operation.
    2. NO  : Go to  F8.
  8. F8 ATTEMPT TO DUPLICATE THE CONCERN WITH THE SHIFT LEVER DISCONNECTED 
    • Disconnect the transfer case shift lever and linkage from the transfer case.
    • Shift the transfer case into the suspect mode (4H or 4L), using the transfer case external control lever.
    • Drive the vehicle to verify if the 4WD system jumps out of gear (attempt to duplicate the customer's concern).
    • Can concern be duplicated with the transfer case shift lever and linkage disconnected? 
    1. YES  : CHECK for internal transfer case damage. REFER to TRANSFER CASE article.
    2. NO  : Go to  F9.
  9. F9 CHECK FOR SHIFT LEVER AND SURROUNDING COMPONENT 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? 
    1. YES  : REPAIR or INSTALL new components as necessary to eliminate the interference(s). TEST the system for normal operation.
    2. NO  : INSTALL a new transfer case shift lever assembly. REFER to TRANSFER CASE article. TEST the system for normal operation.
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