Symptom Chart - Mechanical Shift

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Condition	Possible Sources	Action
The instrument cluster (IC) 4x4 and Low Range indicators do not operate correctly/do not operate	IC Circuitry Mode indication switch (MIS)	Go to Pinpoint Test A .
The vehicle does not shift between 2H and 4H modes correctly	Transfer case. Transfer case shift lever. Manual hublocks. Circuitry.	Go to Pinpoint Test B .
The vehicle does not shift between 4H and 4L modes correctly	Transfer case. Transfer case shift lever. Transmission drag torque.	Go to Pinpoint Test C .
The four wheel drive (4WD) system jumps out of gear	Transfer case. Transfer case shift lever. Manual hublocks.	Go to Pinpoint Test D .
Straightline driveline wind-up	Tire inflation pressure. Tire and wheel size. Tire wear. Axle ratio.	Go to Pinpoint Test E .
Clunking noise during engagement	Vehicle speed. Torque to front axle.	MAKE SURE that the vehicle is shifted at a speed below 5 km/h (3 mph), all tires and wheels are the same size and that the inflation pressures are correct. Also, avoid shifting the transfer case while turning the vehicle.
Transfer case makes noise when driving	Tire inflation pressure. Tire or wheel size.	MAKE SURE that all tires and wheels are the same size and that the inflation pressure are correct.
	Tire tread wear.	CHECK tire tread wear to see if there is more than 1.52 mm (0.06 in) difference in tread wear between front and rear. INTERCHANGE one front and one rear wheel. ROAD TEST again.
	Internal components.	OPERATE the vehicle in all transmission gears. If there is noise with the transmission in NEUTRAL or in some gears and not others, REMOVE and REPAIR the transmission. REFER to AUTOMATIC TRANSAXLE/TRANSMISSION - TORQSHIFT article. If there is noise in all gears, DISASSEMBLE the transfer case. REFER to TRANSFER CASE article. CHECK the planetary gears, bearings, upper and lower drive sprockets and drive chain for damage. INSTALL new parts as necessary. TEST the system for normal operation.
	Fluid level.	FILL the transfer case with automatic transmission fluid. REFER to TRANSFER CASE article.
Unable to duplicate customer concern	4WD system and/or related components.	CARRY OUT the Mechanical Shift On Stop (MSOS) Functional Test. Go to Pinpoint Test F . REFER to INSTRUMENT CLUSTER AND PANEL ILLUMINATION article. REFER to MODULE COMMUNICATIONS NETWORK article.