Symptom Chart - Mechanical Shift

WARNING: This page is about a different car, the 2010 Ford Pickup, 2010 Ford F550 Super Duty, 2010 Ford F450 Super Duty, and 2010 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

SYMPTOM CHART - MECHANICAL SHIFT

Condition	Possible Sources	Action
The Instrument Cluster (IC) 4X4 and low range indicators do not operate correctly/do not operate (manual transfer case only)	IC Circuitry Mode Indication Switch (MIS)	GO to PINPOINT TEST A .
The transfer case 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 8 km/h (5 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 pressures 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 REMOVAL . If there is noise in all gears, DISASSEMBLE the transfer case. REFER to TRANSFER CASE . 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 with the specified fluid. REFER to TRANSMISSION FLUID DRAIN AND REFILL or TRANSFER CASE .
Unable to duplicate customer concern	4WD system and/or related components	CARRY OUT the Manual Shift-On-Stop (MSOS) Functional Test. GO to PINPOINT TEST F .