Drivetrain - Transfer Case Shift Lever Buzz/Howl
Article No.03-9-3
05/12/03
^ TRIM - MANUAL TRANSFER CASE SHIFTER
BUZZ/HOWL AND/OR MANUAL SHIFT BOOT(S)
DETACHMENT - 4X4 FX4 MODELS ONLY
^ NOISE - MANUAL TRANSFER CASE SHIFTER
BUZZ/HOWL AND/OR MANUAL SHIFT BOOT(S)
DETACHMENT - 4X4 FX4 MODELS ONLY
FORD:
2002-2003 RANGER
Article 02-21-10 is being republished in its entirety to update the Service Procedure.
ISSUE
Some 2002-2003 4x4 FX4 Rangers equipped with a manual transfer case, may exhibit a buzz/howl in the transfer case shift lever while driving, and/or shift lever boot detachment due to insufficient retention of the boot(s).
ACTION
Determine if the buzz/howl is coming from the transfer case shift lever. If the source of noise is identified as the transfer case shift lever, replace the D-bushing in the shift linkage.
For vehicles built before 4/30/02, inspect to determine if either or both (transmission and transfer case) shifter lever boot(s), colored black, are loose or unseated. Replace the affected boot(s), per the parts list.
SERVICE PROCEDURE
NOTE
DO NOT REPLACE THE BOOT(S) ON VEHICLES BUILT AFTER 4/30/02 IF THEY ARE NOT LOOSE OR UNSEATED.
1. Remove the shifter knob(s).
NOTE
IF NOT REPLACING THE TRANSMISSION SHIFTER BOOT, DO NOT REMOVE THE TRANSMISSION SHIFTER KNOB OR BOOT.
2. Unsnap the fasteners and pull up on the boot(s) to remove.
NOTE
IF ONLY REPLACING THE BOOT(S)5 PROCEED TO STEP 4.
3. Remove and replace the D-bushing using the following procedure:
a. Remove the two fasteners attaching the upper shift lever to the shift linkage assembly and remove the shift lever.
b. Raise the vehicle.
c. Remove both the large and small bolt attaching the shift linkage assembly to transmission.
d. Slide the D-bushing and shift linkage assembly off of the transfer case shift arm and remove D-bushing.
e. Inspect inner boot to floor pan sealing.
f. Install new service D-bushing part number 3L5Z-7335-AA onto shift linkage assembly and slide back onto transfer case shift arm.
g. Install shift linkage assembly using the Gearshift Linkage Adjustment procedure described in the Workshop Manual section 308-07A.
h. Lower the vehicle.
i. Install upper shift lever with fasteners. Initially torque both fasteners to 10.5 Lb-ft. (14 N.m) and then to 20.5 Lb-ft (27.5 N.m).
4. Install outer boot(s) ensuring that the retaining clips are all properly seated. Pull up on boot(s) so that the top of the boot is about 1 inch from where the lever necks down.
5. Reinstall the knob(s) and tighten.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 02-21-10
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
030903A Replace Manual 0.2 Hr.
Transmission And Or
Manual Transfer Case
Shifter Boot(s)
030903B Replace D-Bushing And 0.6 Hr.
Perform Gearshift
Adjustment Procedure
030903C Replace Manual 0.7 Hr.
Transmission And Or
Manual Transfer Case
Shifter Boot(s) Then
Replace D-Bushing And
Adjust Gearshift
DEALER CODING
CONDITION
BASIC PART NO. CODE
7335 42
OASIS CODES: 508000, 702000