manual transmission and driveline transfer case and 4x4 system repair FCS-14358-REFi gk ig student guide COURSE CODE: 36S08T0 ORDER NUMBER: FCS-14358-REF Updated January, 2006 Ford Customer Service Division Technical Training IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as the personal safety of the individual doing the work This manual provides general directions for accomplishing service and repair work with tested, effective techniques Following them will help assure reliability There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS Each one is there for a specific purpose NOTES give you added information that will help you to complete a particular procedure CAUTIONS are given to prevent you from making an error that could damage the vehicle WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury The following list contains some general WARNINGS that you should follow when you work on a vehicle • • Always wear safety glasses for eye protection • • • To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure • • Do not smoke while working on the vehicle Set the parking brake when working on the vehicle If you have an automatic transmission, set it in PARK unless instructed otherwise for a specific service operation If you have a manual transmission it should be in REVERSE (engine OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific service operation • Keep hands and other objects clear of the radiator fan blades Electric cooling fans can start to operate at any time by an increase in underhood temperatures, even though the ignition is in the OFF position Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood Use safety stands whenever a procedure requires you to be under the vehicle • Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide • Keep yourself and your clothing away from moving parts when the engine is running, especially the fan and belts To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle Tie long hair securely behind your head The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts and/or service department operations These recommendations and suggestions not supersede or override the provisions of the Warranty and Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual shall govern The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approved for printing Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, or testing procedures without notice and without incurring obligation Any reference to brand names in this manual is intended merely as an example of the types of tools, lubricants, materials, etc recommended for use Equivalents, if available, may be used The right is reserved to make changes at any time without notice WARNING: MANY BRAKE LININGS CONTAIN ASBESTOS FIBERS WHEN WORKING ON BRAKE COMPONENTS, AVOID BREATHING THE DUST BREATHING THE ASBESTOS DUST CAN CAUSE ASBESTOSIS AND CANCER Breathing asbestos dust is harmful to your health Dust and dirt present on car wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health when made airborne by cleaning with compressed air or by dry brushing Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers Dust and dirt should be disposed of in a manner that prevents dust exposure, such as sealed bags The bag must be labeled per OSHA instructions and the trash hauler notified as to the contents of the bag If a vacuum bag suitable for asbestos is not available, cleaning should be done wet If dust generation is still possible, technicians should wear government approved toxic dust purifying respirators OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs Only technicians concerned with performing brake or clutch service should be present in the area Copyright © 2002 Ford Motor Company Produced and Coordinated by Technical Support Operations Ford Customer Service Division February, 2002 CUSTOMER EXPECTATIONS Customer Expectations: Service Make it convenient to have my vehicle serviced at your dealership The Service Advisor should Provide me with a clear and thorough explanation of the service performed Call me within a reasonable amount of demonstrate a genuine concern for my service needs time after my service visit to ensure that I'm completely satisfied Fix it right the first time Complete servicing my vehicle in a Be responsive to questions or concerns I bring to your attention timely and professional manner Expectation “Fix It Right The First Time, on Time.” Both service advisors and technicians are important players when it comes to Expectation #3 Why Customers tell us “Fixing It Right The First Time, on Time” is one of the reasons they would decide to return to a dealer to buy a vehicle and get their vehicles serviced Technician Training It is our goal to help the technician acquire all of the skills and knowledge necessary to “Fix It Right The First Time, on Time.” We refer to this as “competency.” Technician’s Role Acquire the skills and knowledge for competency in your specialty via: STST New Model – Self Study – Self Study – FordStar Broadcasts – FordStar Broadcasts – Ford Multimedia Training (FMT) – Instructor Led – Instructor Led The Benefits The successful implementation of expectations means: – Satisfied customers – Repeat vehicle sales – Repeat service sales – Recognition that Ford and Lincoln/Mercury technicians are “the Best in the Business” TABLE OF CONTENTS DAY ONE INTRODUCTION INTRO-1 Day One Flowchart Intro-4 Day One Agenda Intro-5 Prerequisite Review Questions Intro-7 LESSON 1-1 Worksheet A (Video) 4x4 Vehicle Features (Desk) 1-2 Student’s Answer Sheet 1-2 4x4 Driveline 1-4 Transfer Case 1-5 Front Axle 1-6 Front Driveshaft 1-7 Locking Wheel Hubs 1-8 Proper Gear Selections for Driving Conditions 1-10 Mechanical Components 1-11 LESSON 2-1 Powerflow 13-54 Electronic Shift On The Fly (ESOF) Transfer Case 2-2 Powerflow 44-05 Transfer Case 2-4 Powerflow 44-06 Transfer Case 2-6 Powerflow NV273 Transfer Case 2-8 Viscous Coupling 2-10 Worksheet B Viscous Coupling (Desk) 2-12 Student’s Answer Sheet 2-12 Electronic Clutch Assembly 2-14 Worksheet C (Video) A4WD Electronic Clutch (At Desk) 2-16 Student’s Answer Sheet 2-16 2001 Escape Four Wheel Drive (4WD) System 2-17 Operating Modes of the 2001 Escape 4WD System 2-18 2001 Escape Rotary Blade Coupling (RBC) 2-19 2001 Escape Rotary Blade Coupling (RBC) Operation 2-20 2001 Escape Electromagnetic Clutch Operation 2-21 Worksheet D (At Workstation # 1) 13-54 Disassembly & Assembly (Bench) 2-23 Student’s Answer Sheet 2-23 Worksheet E (At Workstation # 2) 44-05 Disassembly & Assembly (Bench) 2-24 Student’s Answer Sheet 2-24 Worksheet F (At Workstation # 3) 44-06 Disassembly & Assembly (Bench) 2-26 Student’s Answer Sheet 2-26 Worksheet G (At Workstation # 4) NV 273 Disassembly & Assembly (Bench) 2-28 Student’s Answer Sheet 2-28 Transfer Case and 4x4 System Repair February, 2002 i TABLE OF CONTENTS DAY TWO INTRODUCTION DAY TWO INTRO-1 Day Two Flowchart Intro-1 Day Two Agenda Intro-2 LESSON 3-1 Front Axles 3-2 Locking Wheel Hub Components 3-4 LESSON 4-1 Diagnostic Process 4-2 Front driveline concerns 4-4 Diagnosing Sub-systems 4-6 Diagnostic Process 4-8 Scan tools 4-10 Normal Operating Characteristics/Customer Concerns 4-10 4WD Concerns 4-11 Hub Diagnosis 4-12 NVH Concerns 4-14 Worksheet H Scan Tool Usage (on Vehicle) 4-17 Student’s Answer Sheet 4-17 Worksheet I Scan Tool Diagnosis (On Vehicle) 4-19 Student’s Answer Sheet 4-19 Worksheet IA Service Publication Navigation (Paper Exercise) 4-21 Student’s Answer Sheet 4-21 Worksheet J 13-54 ESOF (Ranger 4.0L) 4-22 Student’s Answer Sheet 4-22 Worksheet K 44-06 A4WD Expedition 4-23 Student’s Answer Sheet 4-23 Worksheet L (At Bench) Shift Motor Sense Plate Exercise 4-24 Student’s Answer Sheet 4-24 Worksheet M (Desk) Diagnostic Procedure (Paper Exercise) 4-25 Student’s Answer Sheet 4-25 DAY THREE INTRODUCTION INTRO-1 Day Three Flowchart Intro-1 Day Three Agenda Intro-2 ii February, 2002 Transfer Case and 4x4 System Repair DAY ONE INTRODUCTION Manual Transmission and Drivetrain Curriculum The Manual Transmission and Drivetrain Curriculum Path consists of eight courses Each course is one of the following types: Self-Study – This type of course is a self-paced program The technician is responsible for learning the material on his or her own The training material consists of a reference book and accompanying videotape The videotape is designed to support the material in the reference book and should not be used on its own Ford Multimedia Training (FMT) – This type of course is also self-paced The multimedia course allows the technician to interact with the training materials The multimedia course allows the technician to utilize the knowledge attained in the self-study course The FMT concentrates on relationships, such as the cause- andeffect relationships between symptoms and components Distance Learning (FORDSTAR) – This type of course is an instructor-led, interactive type It is presented over the FORDSTAR Distance Learning Network The instructor can present information to, relate questions to, and interact with the technicians Demonstrations and video presentations are used to introduce material Classroom – The classroom course allows for practical, real-world application of skills and knowledge learned in the other courses The eight courses included in the Manual Transmission and Drivetrain Curriculum are as follows: Differential and Driveline Operation – Self-Study Course code: 36S01S0 Differential and Driveline Repair – Classroom Course code: 36S02T0 Manual Transmission/Transaxle Operation – Self-Study Course code: 36S03S0 Manual Transmission/Transaxle Diagnosis – FMT Course code: 36S04M0 Manual Transmission/Transaxle Repair – Classroom Course code: 36S05T0 Transfer Case and 4x4 System Operation – Self-Study Course code: 36S06S0 Transfer Case and 4x4 System Diagnosis – FORDSTAR Course code: 36S07F0 * Transfer Case and 4x4 System Repair – Classroom Course code: 36S08T0 * All students must have completed the Transfer Case and 4x4 System Operation Self-Study Course as well as the Transfer Case and 4x4 System Diagnosis – FORDSTAR prior to enrolling in this course Students who have not completed the previous course should not be admitted to this class Their presence will slow down the course flow, as well as monopolize valuable instructor time Transfer Case and 4x4 System Repair February, 2002 Intro-1 INTRODUCTION DAY ONE Curriculum Goals The goals of this curriculum are: To provide the necessary training to enable the technician to identify, diagnose, and perform timely “Fix It Right The First Time – On Time” repairs Increased customer satisfaction Increased technician productivity Fewer repeat repairs Course Objectives Upon completion of the Transfer Case and 4x4 System Repair Classroom Course, the technician will be able to: Explain the components of a 4x4 system Explain the mechanical components of a transfer case Explain the powerflow of each transfer case used in this course Explain the operation of the viscous coupling Explain the operation of the A4WD electronic clutch assembly Perform transfer case disassembly procedures Perform transfer case inspection procedures Perform transfer case assembly procedures Explain the 4x4 front axles Explain locking wheel hubs Describe the Symptom-to-System-to-Component-to-Cause diagnosis process Perform diagnostic procedures on an electronic transfer case Perform locking hub inspection Intro-2 February, 2002 Transfer Case and 4x4 System Repair DAY ONE INTRODUCTION Audience This course is designed for Ford Motor Company dealer technicians Course Prerequisites Each technician enrolled in this course must meet the following prerequisites: Basic Electrical Part – (self-study) Basic Electrical Part – (FMT) Basic Electrical Part – (classroom) Electronics Part – (self-study) Electronics Part – (FMT) Electronics Part – (classroom) Measuring Devices – (FMT) Noise Vibration & Harshness – (classroom) Transfer Case and 4x4 System Operation – (self-study) Transfer Case and 4x4 System Diagnosis – (Fordstar) Transfer Case and 4x4 System Repair February, 2002 Intro-3 INTRODUCTION DAY ONE DAY ONE FLOWCHART Prerequisite Review: Self-Study and FORDSTAR Start of Class Lecture: 4x4 Components Break Video: 4x4 Basics Worksheet A Lecture: 4x4 Powerflow Video: Viscous Coupling Worksheet B Video: A4WD Worksheet C Rotation #2 Worksheet E Rotation #1 Worksheet D Lunch Break Rotation #3 Worksheet F Rotation #4 Worksheet G End of Day One Intro-4 February, 2002 Transfer Case and 4x4 System Repair Auto: Not Avat’lable Neutral: Not Available No neutral tow kit available for this vehicle Vehicles equipped with a manual transmission can be flat towed with the transmission in neutral and the transfer case in 4x2 mode System Mechanical Information: Shift motor must run to shift from any position to any other position Transfer Case mechanical positions: 4x2 4x4High 4x4Low Front axle mechanical positions: Hubs locked Hubs unlocked Front driveshaft speed synchronization by electromagnetic clutch (ON only during synchronization) Manual shift transfer case is not available Diagnostics: Front or rear driveshafts can be removed for diagnostics when driving in 4x4 high range Most common concerns with this vehicle: Vacuum leaks causing hubs to not lock/unlock 2000 Ranger WITHOUT Pulse Vacuum Hubs Electric Shift: Borg Warner Model 1354 Fluid: Mercon ATF XT-2-QDX Fluid Capacity: 2.54 Pints NOTE: No wiring schematics exist for the 4x4 system without Pulse Vacuum Hubs Therefore all of the following information is ASSUMED to be correct 4x2: Input received from switch GEM runs shift motor to shift transfer case into 4x2 mode Front axle will not disengage - no hubs or disconnect This transfer case is not equipped with an electromagnetic clutch There is no indicator for 4x2 position 4x4 H: Input received from switch GEM runs shift motor to mechanically engage 4x4 high GEM grounds circuit 783 to turn on 4x4 high indicator Circuit 335 is used to signal the RABS module to change to 4x4 strategy 4WABS equipped vehicles NOT receive a signal when 4x4 High is engaged However, the acceleration sensor, or G switch allows the 4WABS to function properly during 4x4 operation The G Switch detects and indicates to the anti-lock brake control module that the vehicle is moving, even if a one wheel lock up has caused all wheels to skid (wheel speed sensors indicating Omph) while the 4x4 is engaged Binding on turns will occur and is NOT based on throttle position input or speed It will occur at any speed or throttle input This transfer case is not equipped with an electromagnetic clutch 4x4 L: Input received from switch GEM runs shift motor to shift transfer case and engage 4x4 low range planetary The GEM grounds circuit 784 to turn on the 4x4 low indicator and signal the PCM to change transmission shift strategy for 4x4 Low Binding, on turns will occur and is NOT based on throttle position input or speed It will occur at any speed or throttle input Low ratio is 2.48:1 This transfer case is not equipped with an electromagnetic clutch Refer to SSM 13745-13746 for stuck in 4x4 Low range or will not shift into 4x4 low range concerns Auto: Not Available Neutral: Not Available No neutral tow kit available for this vehicle Vehicles equipped with a manual transmission can be flat towed with the transmission in neutral and the transfer case In 4x2 mode System Mechanical Information: Shift motor must run to shift from any position to any other position Transfer Case mechanical positions: 4x2 4x4High 4x4 Low Manual shift transfer case is not available Diagnostics: Front or rear driveshafts can be removed for diagnostics when driving in 4x4 high range No common concerns identified for this vehicle 1997-2001 F150-F250 Light Duty Electric Shift: Borg Warner Model 4406-000-022 Manual Shift: Borg Warner Model 4406-000-021 Fluid: Mercon ATF XT-2-QDX or XT-2-DDX Fluid Capacity: 2.0 Pints Mechanical Shift Transfer Case: GEM controls indicators, front center axle disconnect engagement/disengagement, and front driveshaft speed synchronization by transfer case clutch The GEM grounds circuit 210 (with input from either, the 4x4 low-high indicator switch on MSOF or contact plate input on ESOF) to turn on the 4x4 high indicator and signal the ABS module (both RABS and 4WABS) to switch to 4x4 ABS strategy The GEM grounds circuit 975 (97-98MY) or circuit 784(99-00MY) to turn on the 4x4 Low Range indicator For 99-00MY, the PCM receives the ground input on circuit 784, then sends a signal over the SCP bus to the instrument cluster to tum on the indicator The 784 ground signal also switches the PCM transmission shift strategy to 4x4 Low Range and adjusts VSS output (circullit 679) to compensate for low range gear ratio The front driveshaft is synchronized by a momentary 12 volt feed on circuit 779 The GEM grounds either the 4x2 or 4x4 solenoid to engage or disengage the front axle disconnect 4x2 solenoid on entire time vehicle is in 4x2 mode 4x4 solenoid is off in 4x2 mode 4x4 solenoid on entire time vehicle is in 4x4 mode 4x2 solenoid is off in 4x4 mode Electric Shift Transfer Case: 4x2: Input received from switch GEM grounds vacuum solenoid (manifold vacuum) to unlock front axle disconnect GEM shifts transfer case to 4x2 position 4x2 solenoid on entire time vehicle is in 4x2 mode 4x4 solenoid is off in 4x2 mode There is no indicator for 4x2 mode 4x4 H: Input received from switch GEM energizes transfer case clutch relay to synchronize front driveshaft with rear GEM runs shift motor to mechanically engage 4x4 high GEM grounds vacuum solenoid (manifold vacuum) to lock front axle disconnect 4x4 solenoid on entire time vehicle is in 4x4 mode 4x2 solenoid is off The GEM grounds circuit 210 (with input from either the 4x4 low-high indicator switch on MSOF or contact plate input on ESOF) to turn on the 4x4 high indicator and signal the ABS module (both RABS and 4WABS) to switch to 4x4 ABS strategy Binding on turns will occur and is NOT based on throttle position input or speed It will occur at any speed or throttle input 4x4 L: Input received from switch GEM runs shift motor to shift transfer case and engage 4x4 low range planetary GPM grounds vacuum solenoid (manifold vacuum) to lock front axle disconnect 4x4 solenoid on entire time vehicle is in 4x4 mode 4x2 solenoid is off The GEM grounds circuit 975 (97-98 MY) or circuit 784 (99-00MY) to turn on the 4x4 Low Range indicator For 99-00MY, the PCM receives the ground input on circuit 784, then sends a signal over the SCP bus to the instrument cluster to turn on the indicator The PCM must be configured properly to turn on the indicator at the appropriate time for 4x4 vehicles 4x2 vehicle PCM must be configured properly or the 4x4 low indicator will turn on even though it is not equipped The 784 ground signal also switches the PCM transmission shift strategy to 4x4 Low Range and adjusts VSS Binding on turns will occur and is NOT based on throttle position input or speed It will occur at any speed or throttle input Low ratio is 2.64:1 Refer to SSM 13745-13746 for stuck in 4x4 Low range or will not shift into 4x4 low range concerns Auto: Not Available Neutral: Not available on ESOF transfer case, only Mechanical Shift on Fly No neutral tow kit available for this vehicle Vehicles equipped with a manual transmission may be flat towed with the transmission in neutral and the transfer case in 4x2 mode Vehicles equipped with manual shift on the fly transfer case should be flat towed with transfer case in neutral and front axle disconnect vacuum connections capped off System Mechanical Information: Shift motor must run to shift from any position to any other position Transfer case mechanical positions: 4x2 4x4Hiah 4x4Low Front axle mechanical positions: Axle disconnect locked Axle disconnect unlocked Front dniveshaft speed synchronization by electromagnetic clutch (ON only during synchronization) Diagnostics: Front or rear driveshafts can be removed for diagnostics when driving in 4x4 high range Incorrect engagement of transfer case - Inspect Contact plate circuits and swap known good shift motor Most common concerns: Front axle will not enage when shifting on the fly at high speed, but will when shifting, at low speed or stopped - tire sizes or inflation are incorrect 2001 Explorer Sport, Sport Track Electric Shift: Borg Warner Model 1354 Fluid: Mercon ATF XT-2-QDX Fluid Capacity: 3.0 Pints 4x2: Input received firom switch 4x4 Control Module runs shift motor to shift transfer case into 4x2 mode Front axle will not disenage - no hubs or disconnect This transfer case is not equipped with an electromagnetic clutch There is no indicator for 4x2 position 4x4 H: Input received from switch 4x4 Control Module runs shift motor to mechanically engage 4x4 high 4x4CM grounds circuit 783 to illuminate the 4x4 high indicator Binding on turns will occur and is NOT based on throttle position input or speed It will occur at any speed or throttle This transfer case is not equipped with an electromagnetic clutch 4x4 L: Input received from switch 4x4 Control Module runs shift motor to shift transfer case and engage 4x4 low range planetary 4x4CM grounds circuit 784 to illuminate the 4x4 hiah indicator and signal the PCM to change to 4x4 Low Range transmission shift strategy Binding on turns will occur and is NOT based on throttle position input or speed It will occur at any speed or throttle Low Ratio is 2.48:1 This transfer case is not equipped with an electromagnetic clutch Auto: Not Available Transfer case is electronic shift on the fly part time 4x4 only Neutral: Not Available No neutral tow kit available for this vehicle 2001 and 2002 models will not have neutral capability System Mechanical Information: Shift motor must run to shift from any position to any other position Transfer case mechanical positions: 4x2 4x4High 4x4Low Mechanical shift transfer case is not available The four wheel drive control module (4x4CM) is located behind the passenger kick panel Diagnostics: Front or rear driveshafts can be removed for diagnostics when driving in 4x4 high range Contact Plate PID Chart 1999 Expedition/Navigator (NGS Software Level 15.0) 1999 Expedition/Navigator (NGS Software Level 13.0, 14.0) High Auto High Low High Auto High Low Plate A X Open Closed Closed Plate A X Closed Open Open Plate B X Closed Open Open Plate B X Open Closed Closed Plate C X Open Open Closed Plate C X Closed Closed Open Plate D X Open Closed Open Plate D X Closed Open Closed 1999 F-Super Duty 250, 350, 450, 550 (NGS Software Level 15.0) 1999 F-Super Duty 250, 350, 450, 550 (NGS Software Level 13.0, 14.0) High Auto High Low High Auto High Low Plate A Open X Closed Closed Plate A Closed X Open Open Plate B Open X Open Closed Plate B Closed X Closed Open Plate C Closed X Closed Open Plate C Open X Open Closed Plate D Open X Open Open Plate D Closed X Closed Closed 1999 Ranger (NGS Software Level 15.0) 1999 Ranger (NGS Software Level 13.0, 14.0) High Auto High Low High Auto High Low Plate A Open X Closed Closed Plate A Closed X Open Open Plate B Closed X Open Open Plate B Open X Closed Closed Plate C Open X Open Closed Plate C Closed X Closed Open Plate D Open X Closed Open Plate D Closed X Open Closed Contact Plate PID Chart 1999 Explorer/Mountaineer (NGS Software Level 15.0) 1999 Explorer/Mountaineer (NGS Software Level 14.0) High Auto High Low High Auto High Low Plate A X Open Open Closed Plate A X Closed Closed Open Plate B X Closed Closed Open Plate B X Open Open Closed Plate C X Open Open Closed Plate C X Closed Closed Open Plate D X Open Open Open Plate D X Closed Closed Closed 1998 Explorer/Mountaineer (NGS Software Level 13.0, 14.0) 1998 Explorer/Mountaineer (NGS Software Level 15.0) High Auto High Low Plate A X Closed Closed Open Open Plate B X Open Open Closed Open Closed Plate C X Closed Closed Open Open Open Plate D X Closed Closed Closed High Auto High Low Plate A X Open Open Closed Plate B X Closed Closed Plate C X Open Plate D X Open 1997 Explorer/Mountaineer (NGS Software Level 13.0, 14.0) 1997 Explorer/Mountaineer (NGS Software Level 15.0) High Auto High Low Plate A X Closed Closed Closed Closed Plate B X Closed Closed Open Closed Open Plate C X Open Open Closed Open Closed Plate D X Closed Closed Open High Auto High Low Plate A X Open Open Open Plate B X Open Open Plate C X Closed Plate D X Open NOTES: The ESOF locking hubs are triggered by reaulated vacuum; a high of level vacuum (8.5 in-Hg or greater) engages the hubs, and a low level of vacuum (6.5 in-Hg) disengages them Engagement is immediate, but disengagement cannot take place until after the vacuum is released The GEM supplies vacuum for a pre-set time, then releases and vents the wheel ends, after which the hub remains in the selected mode Any malfunction in the control system (GEM, solenoid, electrical harness, vacuum harness) or a related vacuum system (climate control, cruise control) will affect the function of the ESOF hubs It is imperative that these associated systems be certified trouble free before testing the hublock function If the instrument panel 4x4 1ight is not working correctly, look for problems in the electrical system, GEM functions, or transfer case first The instrument panel light responds to these systems, not to the axle or hubs If No 4x4 Engagement: Check Vacuum Sealing at Wheel Ends !!!"!Separate !!!" !!!" !!!" !!!" !!!" vacuum line at frame connection, just to rear of front shock absorber Attach vacuum pump to knuckle side of line Pump to 14 in-Hg, & watch for leak-down Raise wheel on jack, rotate tire, & watch for leak-down Leak-down greater than in-Hg per minute indicates a sealing failure at one or more of the components on that side Refer to workshop manual for pinpoint tests Repeat for other side of vehicle Check Sealing at Vacuum Harness, Reservoir, & Climate Control !!!" !!!" !!!" !!!" !!!" Unplug vacuum harness at solenoid (double line connector) Vacuum test top hose (routing to wheel ends) Vacuum test bottom hose (routing, to reservoir, pump, and A/C system) Note: May require considerable pumping to build vacuum Leak-down greater than in-Hg per minute indicates service required Repair any vacuum leaks before proceeding further Even if other problems exist, vacuum leaks will prevent proper hub ESOF function Perform 4x4 diagnostic tests in workshop manual as required to locate leaks(s) If Hubs Will Not Unlock When Dash Switch Is Set To 4x2: !!!" Verify hub dials are set to “AUTO” (hubs will not disengage in “LOCK” position) all vacuum leak tests listed above Repair any leaks found !!!"!Perform WAIT TWO FULL MINUTES to assure GEM has released vacuum !!!"!Rock vehicle back & forth three times (move to inches only) to relieve bind-up !!!" Verifv hub disengagement by rotating u-joints inboard of knuckle !!!"!If hubs are not disengaged, go to 4x4 diagnostic tests in workshop manual !!!" ROTUNDA TOOL LIST AND ORDER FORM The tools listed below were used during the presentation of this course It is essential that correct tools be used during transmission service and repair For your convenience, the tools are listed below and a Rotunda Order Form can be found on the following pages Tools • Jaw Puller D97L-4221-A [205-D072] • Bench Mounted Holding Fixture 307-003 (T57L-500-B) • Companion Flange Holding Tool T78P-4851-A [205-126] • Flange Remover 205-076 • Front Output Shaft Snap Ring Protector Sleeve 308-405 • Input Gear Snap Ring Protector Sleeve 308-406 • Oil Suction Gun (D94T-9000-A) • Rear Output Shaft Snap Ring Protector Sleeve 308-404 • Sector Shaft Nut Socket 308-407 • Transfer Case Housing Spreader 308-396 ORDER FORM ITEM NUMBER QTY PREFIX BAL OF NO PART I ADDITIONAL SPECIFICATIONS (if required) COL COL OPTIONAL: CATALOG PAGE NO FAX NUMBER 1-800-762-6181 DESCRIPTION EXTENDED TOTAL UNIT PRICE TOTAL PART II Buyer, having been quoted both an installment Price and a lesser Cash Price, hereby purchases from Seller on installment price basis, upon the terms and conditions set forth on the face hereof, the equipment to be delivered and installed at Buyer’s premises, as described above and agrees to pay Seller the Installment Price therefore as so set forth until paid in full Dealer Parts Code #: Dealer Name: Address: ❏ 30 Day Open Account City, State, Zip: Installment Plan (Fixed Rate) ❏ 12 Mo (Minimum $1,000) ❏ 24 Mo (Minimum $3,000) ❏ 48 Mo (Minimum $10,000) ❏ 60 Mo (Minimum $15,000) (Reverse side must be completed) Phone #: Fax #: PART III ❏ 36 Mo (Minimum $5,000) Attention: (ORDERS OVER $4,000) FCSD CREDIT MANAGER APPROVAL Notice To Buyer: Order Date: Ship to arrive by (Date or ASAP): Address: City, State, Zip: Do not sign this contract before you read it or if it contains any blank spaces You are entitled to an exact copy of the contract you sign Under the law you have the right to pay off in advance the full amount due and under certain circumstances to obtain partial refund of the time charge BUYER ACKNOWLEDGES RECEIPT OF A TRUE AND COMPLETELY FILLED IN COPY OF THIS CONTRACT AT THE TIME OF SIGNING May 2000 315-195 Prices subject to change without notice PRINT NAME AUTHORIZED DEALERSHIP SIGNATURE (BUYER) DEALER: Be sure you have completed Parts I and II for all orders, Part III for Installment Plan Orders 315-195 (Previous editions may not be used) FOR TELEPHONE ORDERS USE THE ROTUNDA TOLL-FREE NUMBER 1-800-ROTUNDA (768-8632) TERMS & CONDITIONS Payment and Terms of Payment a If Buyer has requested the Dealer Open Account payment plan via the Ford Dealer Statement in Part II of the order form, and Seller agrees to sell pursuant to such plan, then Buyer shall pay the total purchase price shown on the invoice b If Buyer has requested the Installment Plan (Fixed Rate) in Part II of the order form, and Seller agrees to sell pursuant to such Plan, then Buyer shall pay the Down Payment (if any), and the Time Balance in equal monthly installments in accordance with the terms set forth below c If Buyer has requested the Installment Plan (Variable Rate) in Part II of the order form, and Seller agrees to sell pursuant to such Plan, then Buyer shall pay the Total Cash Price and any interest thereon in accordance with the Loan and Security Agreement to be executed by Buyer and Seller Title Title to Equipment purchased by Buyer from Seller shall pass to Buyer upon Seller’s receipt of all amounts owing by Buyer to Seller hereunder Risk of Loss Seller shall be responsible for risk of loss until Equipment is delivered to the location set forth herein, at which time risk of loss shall be the responsibility of Buyer Acceptance and Inspection Buyer shall be deemed to have accepted Equipment upon Seller’s delivery Equipment shall be deemed to have been delivered in good condition unless Buyer gives Seller notice to the contrary within 10 days after Seller’s delivery Delays Seller shall not be liable for any failure or delay in delivering Equipment, or for any failure to perform any provision hereof, resulting from fire, flood or other casualty, riot, strike or other labor difficulty, governmental regulation or other restriction, or any other cause beyond Seller’s control Unconditional Obligation Buyer’s obligation to make payments to Seller or its assignee shall be absolute and unconditional and shall continue unmodified despite any loss, damage or other interruption in the use of Equipment The obligation of Buyer to pay in full any amounts due under this contract shall not be subject to dispute, claim, counterclaim, defense or other right which Buyer may have to assert against Seller or the manufacturer of Equipment Buyer acknowledges that: (a) Buyer has selected Equipment and Manufacturer, and Buyer has determined Equipment’s suitability and fitness for the Buyer’s purpose, (b) Seller is not the manufacturer of Equipment, and (c) Manufacturer issues its own warranty and performs the obligations under such warranty Warranty THE MANUFACTURER’S WARRANTY SHALL BE BUYER’S EXCLUSIVE REMEDY, RECOURSE OR DAMAGE FOR ANY DEFECT IN WORKMANSHIP OR MATERIAL OR ANY FAILURE OF THE EQUIPMENT SELLER MAKES NO WARRANTIES, REPRESENTATIONS, INDEMNITIES OR GUARANTEES WHATSOEVER WITH RESPECT TO EQUIPMENT EITHER EXPRESS OR IMPLIED, ARISING BY LAW OR CUSTOM, INCLUDING ANY IMPLIED WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE THE LIABILITY OF THE SELLER SHALL BE LIMITED TO EXPRESS OBLIGATION TO DELIVER THE EQUIPMENT UNDER NO CIRCUMSTANCES SHALL SELLER BE LIABLE OR RESPONSIBLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL, CONSEQUENTIAL OR PUNITIVE DAMAGES, WHETHER FORESEEABLE OR UNFORESEEABLE, WHICH BUYER MAY INCUR, EXPERIENCE OR CLAIM, INCLUDING, BUT NOT LIMITED TO, CLAIMS FOR LOSS OF PROFITS, INTERRUPTION IN BUSINESS, LOST OPPORTUNITY, WORK STOPPAGE OR OTHER IMPAIRMENT OF ASSETS, ARISING OUT OF MISREPRESENTATION, NEGLIGENCE, STRICT LIABILITY, IN TORT OR OTHERWISE, ON ACCOUNT OF ENTERING INTO OR RELYING ON THIS AGREEMENT, EVEN IF SELLER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES Freight and Taxes Freight costs and applicable taxes will be added to the final invoice and will be borne by Buyer Security Interest Buyer hereby grants to Seller a continuing security interest in the Equipment, including all products and proceeds thereof, until all amounts due hereunder are paid Buyer agrees to execute, and pay filing fees for, any financing statement or other documents deemed necessary by Seller to maintain a valid security interest in the Equipment 10 Maintenance Buyer shall use the Equipment carefully and properly Buyer, at Buyer’s own expense, shall maintain and repair all items of the Equipment in order to keep them in good order and condition and, in particular, shall comply fully with the maintenance, operating, usage or other instructions provided by the manufacturer Buyer authorizes Seller, or any third party appointed by Seller, to inspect the Equipment when necessary Buyer shall at all times keep the Equipment free and clear of all liens, charges or encumbrances 11 Personal Property Ford proprietary diagnostic equipment (including the software, if applicable) shall be kept at Buyer’s premises as listed on the reverse side and shall remain personal property regardless of how and to what degree it may be affixed or attached to any building or structure or what may be the consequence of its removal from such building or structure Buyer shall not encumber the Equipment (including software, if applicable) until all amounts owing to Seller hereunder are paid In addition, Seller grants to Buyer, and Buyer accepts, a non-exclusive license to use the Equipment (including the software, if applicable) in accordance with the terms and conditions set forth herein The license (and Equipment) shall not be leased, sold, assigned or otherwise transferred, in whole or in part In the event, Buyer proposes to lease, sell assign or otherwise transfer the Equipment (and/or its software, if applicable), in whole or in part, to any person or entity, Ford Motor Company shall have a Right of First Refusal to purchase the Equipment (including all software, if applicable) for Ten and 00/100 Dollars ($10.00) in U.S currency 12 Insurance and Indemnification Buyer shall defend, indemnify and hold harmless Seller from and against, and at Buyer’s own expense provide insurance satisfactory to Seller covering any and all losses, damages, claims, expenses and other liabilities (including attorney’s fees,) relating to or arising out of: (I) damage, loss, theft, or destruction of the Equipment, or (ii) death, injury or property damage connected with the use, operation or condition (including without limitation, defects whether or not discoverable by any party) of the Equipment Buyer shall promptly notify Seller of any such claim Seller shall have the right to participate, at its own expense, in any proceeding for which Buyer has undertaken the defense of Seller, and in no event shall Buyer settle any claim against Seller without Seller’s prior written consent, Buyer shall provide evidence of such insurance to Seller upon demand Seller is under no obligation to examine any insurance certificate or advise Buyer that its insurance does not comply with the requirements set forth herein The losses covered by insurance shall in all cases be payable to Seller and Buyer as their interests may appear If Buyer fails to insure the Equipment as herein provided, Seller may, but is not obligated to, place such insurance upon the Equipment and the Buyer agrees to pay to Seller on demand the premiums for such insurance placed by Seller In no event shall any insurance coverage be deemed to limit or replace Buyer’s obligation to indemnify Seller as provided herein 13 Default In the event that Buyer: (a) fails to pay any amount due hereunder within ten (10) days of the due date, (b) fails to comply with any other provision hereof, (c) files, or if there is filed against Buyer, any petition under any bankruptcy or insolvency laws or suffers the appointment of any trustee or receiver for all or any part of Buyer’s business or assets, or (d) has any assignment (voluntarily or involuntarily), lien, attachment or levy issued against the Equipment (unless such petition, assignment or appointment, lien, attachment or levy is withdrawn or nullified within twenty (20) days) then Buyer shall be in default hereunder and all of Buyer’s indebtedness and obligations to Seller shall, at Seller’s option, become immediately due and payable, and Seller may, at its option, terminate this contract and repossess any and all items of Equipment with or without legal process and sell the same at private or public sale without prior notice to Buyer to the extent permitted by law Upon request, Buyer shall deliver the Equipment to Seller at a place designated by Seller Repossession and/or sales of the Equipment upon such default shall not affect the Seller’s right to retain all payments made prior to repossession or to recover the balance due hereunder for any deficiency Buyer shall reimburse Seller all costs of collection, repossession and resale (including reasonable attorneys’ fees, court costs and other expenses incurred by Seller.) Buyer hereby releases Seller from any liability for damages resulting from repossession hereunder The rights and remedies of Seller, in the event of default herein mentioned shall not be deemed exclusive but shall be cumulative and in addition to all other rights and remedies existing under law, and may be enforced successively or concurrently Waiver by Seller of any default shall not be deemed a waiver of any other default 14 General The waiver by either party of, or failure to claim, a breach of any provision of this contract shall not be deemed to be a waiver of any provision of this contract, shall not be deemed to be a waiver of any subsequent breach or to affect in any way the effectiveness of such provision This contract constitutes the entire agreement between the parties and may not be changed except by an instrument in writing signed by the party to be charged This contract may not be assigned by Buyer without the Seller’s prior written consent Seller may assign this contract at any time but shall not thereby be relieved from any liability hereunder In the event that one or more clauses of this contract are found to be unenforceable, illegal or contrary to public policy by court of competent jurisdiction, the remainder of this contract shall remain in full force and effect except for the unenforceable, illegal or other provisions This agreement is a Michigan agreement and shall be interpreted, construed and enforced in accordance with the laws of the State of Michigan, United States of America Each of the parties here to agrees that any legal or equitable action or proceeding with respect to this agreement shall be brought only in any court of the State of Michigan, or in any court of the United States of America sitting in Michigan, and each of the parties hereto submits to and accepts generally and unconditionally the jurisdiction of those courts with respect to such party’s person and property Each party hereby irrevocably waives any objection to the laying of venue of any such action or proceeding in the above described courts 15 Finance Charge Monthly portion of Finance Charge (Part III, Item 3) due is calculated each month by multiplying 1/12 of the annual finance charge rate times the remaining portion of the Unpaid Balance of Cash Price, and is added to the portion of the Unpaid Balance of Cash Price due each month PART III Installment Plan Agreement Cash Price $ Down Payment (if any) $ Unpaid Balance of Cash Price (Difference between and 2) $ Finance Charge (Finance charge will reduce each month) Call 1-800-768-8632 for the current finance charge rate $ Time Balance (3 + 4) $ Number of Installments ❏ 12 ❏ 24 ❏ 36 ❏ 48 ❏ 60 equal monthly installments Taxes and transportation (if any) will be billed separately Installment Payment Price (1 + 4) $ I agree to pay the time Balance set forth in accordance with the above schedule and the terms and conditions of this order form Dealer Signature: Date: MAIL COMPLETED ORDER FORM TO: ROTUNDA EQUIPMENT PROGRAM P.O Box 1450 Kenosha, WI 53141 September 1999 315-195 Prices subject to change without notice ... Vibration & Harshness – (classroom) Transfer Case and 4x4 System Operation – (self-study) Transfer Case and 4x4 System Diagnosis – (Fordstar) Transfer Case and 4x4 System Repair February, 2002 Intro-3... * Transfer Case and 4x4 System Repair – Classroom Course code: 36S08T0 * All students must have completed the Transfer Case and 4x4 System Operation Self-Study Course as well as the Transfer. .. as a transfer case, a front driveshaft, and a front drive axle (with or without locking hubs) 1-4 February, 2001 Transfer Case and 4x4 System Repair DAY ONE LESSON TRANSFER CASE CRTC006-A Transfer