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Home >> Ford >> 2012 >> Explorer Base, 3.5 8, AWD, 6F50 >> Repair and Diagnosis >> External Pages >> Different car >> Section 53 (Four Wheel Drive (4WD) Systems) >> Diagnosis And Testing >> Four Wheel Drive (4WD) Systems - Mechanical Shift >> Pinpoint Tests >> Pinpoint Test D: The Transfer Case Jumps Out of Gear >> Pinpoint Test D: The Transfer Case Jumps Out Of Gear

Pinpoint Test D: The Transfer Case Jumps Out Of Gear

WARNING: This page is about a different car, the 2013 Ford F-550 Super Duty, 2013 Ford F-450 Super Duty, 2013 Ford F-350 Super Duty, and 2013 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: When directed to drive the vehicle as part of this test, drive the vehicle on a hard surface in an area without traffic to prevent a crash. Failure to follow these instructions may result in personal injury.
NOTE: Vehicles equipped with the Manual Shift-On-Stop (MSOS) system and manual hublocks should not be operated in 4H or 4L mode with the hublocks set to the FREE position. Doing so can result in damage to driveline components.
NOTE: 4H (4X4 HIGH) and 4L (4X4 LOW) are not intended for driving on hard/dry surfaces.
  1. D1 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 D2.
  2. D2 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 115 Nm (85 lb-ft) ± 9 Nm (80 lb-in)? 
    • Yes  : GO to  D5.
    • No  : GO to D3.
  3. D3 CHECK THE SHIFT LEVER RESIDUAL TORQUE 
    • Tighten the shift lever assembly-to-transmission bolt to 115 Nm (85 lb-ft).
    • Cycle the shift lever several times.
    • Using a torque wrench, check the shift lever assembly-to-transmission bolt torque.
    • Is the bolt torque greater than 108 Nm (80 lb-ft)? 
    • Yes  : GO to D4.
    • 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. D4 VERIFY IF THE CONCERN IS STILL PRESENT 
    • Drive the vehicle to verify if the Four-Wheel Drive (4WD) system jumps out of gear (attempt to duplicate the customer's concern).
    • Is the concern still present? 
    • Yes  : GO to D5.
    • No  : RETURN the vehicle to the customer. The concern may have been caused by incorrect shift lever bolt torque.
  5. D5 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 a suitable wrench.
    • Drive the vehicle to verify if the 4WD system jumps out of gear (attempt to duplicate the customer's concern).
    • Is the concern still present? 
    • Yes  : GO to PINPOINT TEST A . CHECK specifically for Manual Shift-On-Stop (MSOS) mode indication switch and/or associated wiring problems. If no faults are found, REPAIR the transfer case.
    • No  : GO to D6.
  6. D6 CHECK FOR SHIFT LEVER 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  : CHECK the motor mounts and the transmission mount. REPAIR or INSTALL new components as necessary to eliminate the interferences. 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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