Explorer Sport Trac 4WD V6-4.0L VIN K Flex Fuel (2004)
Transfer Case Actuator: Customer Interest
4X4 System - No or Intermittent Engagement
TSB 04-18-10
09/20/04
4X4 NOT ENGAGING OR INTERMITTENT 4X4 ENGAGEMENT - VEHICLES BUILT PRIOR TO 4/1/2004
FORD:
2003-2004 Explorer Sport Trac
ISSUE
Some 2003-2004 Sport Trac 4X4 Vehicles built prior to 4/1/2004, may exhibit the 4X4 not engaging, or intermittent 4X4 engagement. In some
instances, when the vehicle is shifted from 2WD to 4WD high, the 4X4 indicator may illuminate but the vehicle will not mechanically be in 4WD high. If
this occurs and the vehicle can be successfully shifted from 2WD high to 4WD low, this is an indication that the transfer case shift fork may be the cause.
ACTION
Refer to the following Service Procedure.
SERVICE PROCEDURE
1.
Attempt to duplicate the condition by shifting the vehicle into 4WD high multiple times.
a.
If the condition can be verified as stated in the ISSUE proceed to Step 3.
b.
If the condition cannot be verified as stated in the ISSUE, but other 4WD shift concerns are verified (such as not shifting into 4WD low, or
not shifting into 4WD high and 4WD Low) proceed to Step 2.
c.
If no concerns can be verified return the vehicle to the customer.
2.
Perform normal diagnosis beginning with pinpoint test "A" from Section 308-07A of the Workshop Manual. Verify that the condition is not
related to any electronic components. During normal diagnostics, if it cannot be determined whether the shift motor is operating properly, remove
the motor. With the motor removed but still electrically connected perform a functionality check. Repair any wiring and/or electrical components
as necessary. Reevaluate the vehicle, if the condition is corrected return vehicle to customer. If the condition is not corrected proceed to Step 3.
3.
If all electronic components are operational and the vehicle still does not shift into 4WD or exhibits intermittent engagement, replace the transfer
case shift fork. Refer to Workshop Manual Section 308-00. After repair, verify operation of 4X4 system.
PARTS BLOCK
WARRANTY STATUS:
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO.
CODE
7289
07
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