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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 977 (Four-Wheel Drive Systems (ESOF) -- F150 Pickup) >> Diagnosis And Testing >> Four-Wheel Drive Systems - Mechanical Shift >> Pinpoint Tests >> Pinpoint Test F: The 4x4 System Jumps Out Of Gear >> PINPOINT TEST F: THE 4x4 SYSTEM JUMPS OUT OF GEAR

PINPOINT TEST F: THE 4x4 SYSTEM JUMPS OUT OF GEAR

WARNING: This page is about a different car, the 2005 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? 
    • Yes  : REPAIR or INSTALL new component(s) as necessary. TEST the vehicle for normal operation.
    • 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 Nm (86 lb-ft) +/- 9 Nm (7 lb-ft)? 
    • Yes  : GO to  F5.
    • No  : GO to F3.
  3. F3 CHECK THE SHIFT LEVER RESIDUAL TORQUE 
    • Tighten the shift lever assembly-to-transmission bolt to 117 Nm (86 lb-ft).
    • Cycle the shift lever several times.
    • Using a torque wrench, check the shift lever assembly-to-transmission blot torque.
    • Is the bolt torque greater than 108 Nm (80 lb-ft)? 
    • Yes  : GO to  F4.
    • 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. F4 VERIFY THAT THE CONCERN IS STILL PRESENT 
    • Connect the scan tool.
    • Monitor the MSS PIDs.
    • 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  F5.
    • 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? 
    • Yes  : GO to  F6.
    • 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 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 intermittent MSS and or associated wiring problems.
    • 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 steps 1, 2 and 3 for the RH side of the vehicle.
    • Were the vent lines obstructed (can a vacuum be held)? 
    • Yes  : INSTALL new IWE vent lines as necessary. TEST the system for normal operation.
    • 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 4x4 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? 
    • Yes  : CHECK for internal transfer case damage. REFER to TRANSFER CASE .
    • 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? 
    • Yes  : REPAIR or INSTALL new components as necessary to eliminate the interference(s). 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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