Symptom Chart - Mechanical Shift

WARNING: This page is about a different car, the 2012 Ford Pickup, 2012 Ford F550 Super Duty, 2012 Ford F450 Super Duty, and 2012 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 Four-Wheel Drive (4WD) indicators do not operate correctly	Wiring, terminals or connectors Mode Indication Switch (MIS) Instrument Panel Cluster (IPC)	GO to PINPOINT TEST A .
The vehicle does not shift between 2H and 4H modes correctly	Shift lever assembly Transfer case internal components Manual hublocks Front axle assembly	GO to PINPOINT TEST B .
The vehicle does not shift between 4H and 4L modes correctly	Transmission neutral drag torque Shift lever assembly Transfer case internal components	GO to PINPOINT TEST C .
The transfer case jumps out of gear	Shift lever detent MIS Shift lever assembly Transfer case	GO to PINPOINT TEST D .
Vehicle pulsates or shudders in a straight line (straight line driveline wind up)	Unmatched tire sizes Unequal amounts of tire wear Unequal tire inflation pressures Unmatched front and rear axle ratios Front and rear axles	GO to PINPOINT TEST E .
Clunking noise during transfer case engagement	Vehicle speed Torque to front axle	MAKE SURE that the vehicle is shifted at a speed below 5 km/h (3 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 (4WD system) makes noise when driving	Unequal tire inflation pressures Unmatched tire sizes	MAKE SURE that all tires and wheels are the same size and that the inflation pressures are correct.
	Unequal amounts of tire 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.
	Transfer case 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 AUTOMATIC TRANSAXLE/TRANSMISSION TORQSHIFT or AUTOMATIC TRANSAXLE/TRANSMISSION TORQSHIFT . 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 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 .