Symptom Chart - AWD

WARNING: This page is about a different car, the 2004 Mercury Mountaineer and 2004 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.

SYMPTOM CHART - AWD

Condition	Possible Sources	Action
The transfer case makes noise	Tire inflation pressure. Tire and wheel size.	MAKE SURE that all tires and wheels are the same size and that the inflation pressures are correct.
	Tire tread wear.	CHECK tire tread wear to see if there is more than 0.15 mm (0.06 in) difference in tread wear between front and rear. INTERCHANGE one front wheel and one rear wheel. Road test again.
	Internal components.	OPERATE the vehicle in all transmission gears. If there is noise in the transmission in NEUTRAL, or in some gears and not in others, REMOVE and REPAIR the transmission. REFER to AUTOMATIC TRANSMISSION - 5R55S . If there is noise in all gears, DISASSEMBLE the transfer case. Refer to TRANSFER CASE - AWD . CHECK the planetary gears, the bearings, the upper and lower drive sprockets and drive chain for damage. INSTALL new parts as necessary.
	Fluid level.	FILL with automatic transmission fluid. refer to TRANSFER CASE DRAINING AND FILLING .
Wheel/tire bounce, vehicle skip	Internal components.	OPERATE the vehicle in all transmission gears. If there is noise in the transmission in NEUTRAL, or in some gears and not in others, REMOVE and REPAIR the transmission. REFER to AUTOMATIC TRANSMISSION - 5R55S . If there is noise in all gears, DISASSEMBLE the transfer case. refer to TRANSFER CASE - AWD . CHECK the planetary gears, the bearings, the upper and lower drive sprockets and drive chain for damage. INSTALL new parts as necessary.
Wheel/tire bounce, vehicle skip	Tire tread wear.	MAKE SURE that all tires and wheels are the same size and that inflation pressures are correct. REFER to SUSPENSION SYSTEM .
Leaking automatic transmission fluid (ATF) from vent	Transfer case.	DRAIN the fluid to the correct level. refer to TRANSFER CASE DRAINING AND FILLING .
Leaking automatic transmission fluid (ATF) from vent	Vent tube.	REPAIR or INSTALL a new vent tube. REFER to TRANSFER CASE .
Leaking automatic transmission fluid (ATF) from transfer case housing	Transfer case housing bolts.	TIGHTEN the bolts to specification. REFER to TORQUE SPECIFICATIONS .
	Sealant.	REBUILD with black non-acid cure silicone gasket and sealant. refer to TRANSFER CASE - AWD .
	Fluid.	DRAIN fluid and FILL with automatic transmission fluid. refer to TRANSFER CASE DRAINING AND FILLING .
	Transfer case gasket.	INSTALL a new transfer case gasket. REFER to TRANSFER CASE .
Leaking automatic transmission fluid (ATF) output shaft seals	The vent is plugged.	REPAIR the plugged vent.
	Output shaft seals.	INSTALL a new output shaft seal. REFER to TRANSFER CASE .
The front axle does not engage correctly	Front axle.	REFER to DRIVELINE SYSTEM .
The front axle does not engage correctly	Transfer case clutch. Internal components.	DISASSEMBLE the transfer case. refer to TRANSFER CASE - AWD . CHECK the planetary gears, the bearings, the upper and lower drive sprockets and drive chain for damage. INSTALL new parts as necessary.