Symptom Chart - Mechanical Shift

WARNING: This page is about a different car, the 2003 Ford Pickup, 2003 Ford F550 Super Duty, 2003 Ford F450 Super Duty, 2003 Ford Excursion, and 2003 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
Transfer case makes noise	Tire or wheel size.	VERIFY all tires and wheels are the same size and tire pressure is correct.
	Excessive tire tread wear.	CHECK tire tread wear to see if there is more than 0.15 cm (0.06 inch) difference in tread wear between front and rear. EXCHANGE one front and one rear wheel. INFLATE tires to correct specifications.
	Internal components.	CYCLE the transmission through all gear positions with the transfer case in 2WD and 4X4. If there is noise in the NEUTRAL position or in some gears but not others, DIAGNOSE the transmission. If there is noise in all transmission gear positions, OPERATE the transfer case in all positions. If the noise is only present in 4X4, during acceleration, deceleration and float, DISASSEMBLE the transfer case; REFER to OVERHAUL - T/C (NV271 & NV273) . CHECK the internal components for damage. REPAIR as necessary. If the noise is only present in 4X4 LOW, INSPECT the planet gears and range sleeve for damage. REPAIR as necessary.
Transfer case jumps out of gear	Shift linkage.	CHECK shift linkage travel. ADJUST the shift linkage as necessary, REFER to GEARSHIFT LINKAGE ADJUSTMENT .
	Front and rear driveshaft slip yokes.	LUBRICATE and REPAIR the slip yoke as necessary.
	Internal components.	REPAIR the transfer case as necessary, REFER to OVERHAUL - T/C (NV271 & NV273) .
Excessive driveline/torsional wind-up during straight-line operation	Tire and wheel size mismatched.	VERIFY all tires and wheels are a matching size and that inflation pressures are correct.
	Mismatched axle ratios.	VERIFY front and rear axle ratios are the same.