36S17T0 Diff - 4WD Diagnosis and Repair - REF

Differential and
4WD Systems
Diagnosis and Repair
36 - Manual Transmission & Drivetrain
Student Guide
P
R
N
D
2
1
FCS-12973-REF
Course Code: 36S17T0
January 2008
Ford Customer Service Division

Technical Training
Blank
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.
Use safety stands whenever a procedure requires you
to be under the vehicle.
Be sure that the ignition switch is always in the OFF
position, unless otherwise required by the procedure.
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.
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 help prevent serious burns, avoid contact with hot

metal parts such as the radiator, exhaust manifold, tail
pipe, catalytic converter and muffler.
Do not smoke while working on the vehicle.
To help 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.
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.
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 do 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.
DANGER: Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure to excessive amounts of dust may be a potential cancer and lung disease
hazard. Exposure may also cause irritation to skin, eyes, and respiratory tract, may cause allergic reactions, and/or may lead to other
chronic health effects.
Do not breathe dust. Do not use compressed air to blow dust from storage containers or friction components. A high-efficiency
(HEPA) vacuum cleaner should be used carefully to remove dust. Adherent dust should be removed with a damp rag.
If inhaled, remove to fresh air. If irritation persists, seek medical attention or advice.
If dust gets in eyes, irrigate under eyelids with water for 15 minutes and seek medical attention.
Copyright 2007 Ford Motor Company
Produced and Coodinated by

Technical Support Operations
Ford Customer Service Division
January 2008
CUSTOMER EXPECTATIONS
Customer Expectations: Service
1. Make it convenient to have my vehicle

serviced at your dealership.
2. The Service Advisor should demonstrate

a genuine concern for my service needs.
3. Fix it right the first time, on time.

4. Complete servicing my vehicle in a
timely and professional manner.
5. Provide me with a clear and thorough

explanation of the service performed.
6. Call me within a reasonable amount of

time after my service visit to ensure that
I'm completely satisfied.
7. Be responsive to questions or concerns

that I bring to your attention.
Expectation #3
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.
Technicians Role
Acquire the skills and knowledge for competency in your specialty via:
STST
New Model
Web-Based
Web-Based
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
DIFFERENTIAL AND 4WD SYSTEMS DIAGNOSIS AND REPAIR
TABLE OF CONTENTS
IINTRODUCTION .............................................................................................. INTRO - 1

Differential and 4WD Systems Diagnosis and Repair ............................................................. Intro - 2
Course Description ............................................................................................................ Intro - 2
Course Requirements ........................................................................................................ Intro - 3
Course Objectives .............................................................................................................. Intro - 3
Course Agenda .................................................................................................................. Intro - 3
LESSON 1 ................................................................................................................ 1 - 1
Prerequisite Review ...................................................................................................................... 1 - 2
Theory and Operation Questions ........................................................................................... 1 - 2
Diagnosis and Repair Questions ............................................................................................ 1 - 3
Differential/Driveline Diagnosis, Measurements, Adjustments ............................................... 1 - 4
LESSON 1 WORKSTATIONS .................................................................................... 1 - 6

Workstation 1 Ford 8.8 in. Axle Assembly .................................................................................... 1 - 7
Workstation 2 Ford 9.75 in. Axle Assembly ................................................................................ 1 - 10
LESSON 2 ................................................................................................................ 2 - 1
Prerequisite Review ...................................................................................................................... 2 - 2
Theory and Operation Questions ........................................................................................... 2 - 2
AWD Components/Operation ................................................................................................. 2 - 4
LESSON 2 WORKSTATIONS .................................................................................... 2 - 6

Workstation
Workstation
Workstation
Workstation
1,
2,
3,
4,
4406 Disassembly and Assembly ........................................................................ 2 - 7

4405 Disassembly and Assembly ........................................................................ 2 - 8
4WD PID Navigation ............................................................................................. 2 - 9
4WD PID Navigation ........................................................................................... 2 - 11
LESSON 3A WORKSTATIONS ................................................................................. 3 - 1

Workstation 1A, Traction-Lok Axle Disassembly and Assembly .................................................. 3 - 2
Workstation 2A, 4WD Concern ..................................................................................................... 3 - 4
Workstation 3A, AWD PID Data Analysis ..................................................................................... 3 - 6
LESSON 3B WORKSTATIONS ................................................................................. 3 - 9

Workstation
Workstation
Workstation
Workstation
1B,
2B,
3B,
4B,
4WD Concern ................................................................................................... 3 - 10

Service Publications Navigation 4WD PID Recordings ................................ 3 - 11
4WD Concern ................................................................................................... 3 - 12
Service Publications Navigation 2007 AWD ................................................. 3 - 13
LESSON 4 ................................................................................................................ 4 - 1
Workstation 1, Service Publications Navigation - 4WD Ranger ................................................... 4 - 2
Workstation 2, Driveshaft Angle Measurement ............................................................................ 4 - 3
Workstation 3, Service Publications Navigation - 4WD Ranger ................................................... 4 - 4
Differential and 4WD Systems Diagnosis and Repair
TOC - i
September 2007
TABLE OF CONTENTS
Blank
TOC - ii
September 2007
INTRODUCTION
INTRODUCTION
Intro - 1
September 2007
INTRODUCTION

Course Description
Rear Axle (Left) and Transfer Case (Right)

This instructor-led course is part of the Ford Manual Transmission and Drivetrain curriculum (Specialty 36). It is
a four-day course facilitated by an instructor. This course is designed to provide hands-on opportunities for
technicians to learn and improve their skills using tools and equipment, and to apply knowledge learned in
prerequisite courses. Each day, you will have multiple opportunities to practice selected skills. The results of
your work are recorded on worksheets.
Intro - 2
September 2007
INTRODUCTION
Course Requirements
Each technician attending this course is required to pass a combination of hands-on and written evaluations. These are
administered after all lectures, demonstrations and/or practice sessions have been completed.
The hands-on evaluation is a pass/fail type. It is conducted with exercises in differentials, axles, and selected
diagnostic procedures, and it covers:
pinion gear shim selection
gear pattern evaluation
service publications navigation
selected special tool usage
4WD On-Vehicle Diagnosis
To pass the course, you must demonstrate 100% mastery of the skills covered in the Hands-On Post-Test
exercises AND you must correctly answer at least 80% of the Written Post-Test questions.
Course Objectives
Upon successful completion of this course, you will be able to:
identify axle/differential and driveline diagnostic procedures.
perform selected driveshaft diagnostic procedures.
identify key axle and differential service procedures.
perform selected axle and differential service procedures.
diagnose RWD-based and FWD-based 4WD system concerns using IDS PID data recordings.
perform RWD-based 4WD transfer case and 4WD system diagnosis on a vehicle.
perform RWD-based 4WD transfer case service procedures.
Course Agenda
Introductions
LESSON 1: Prerequisite Review (Driveline and Axles), Conventional Axle Assembly Workstations, Workstation
Review
LESSON 2: Prerequisite Review (Transfer Case and 4WD Systems), Workstations (Transfer Case
Disassembly and Assembly, Scan Tool Usage and PID Navigation), Workstation Review
LESSON 3A: Workstations (Traction-Lok Differential Disassembly and Assembly, 4WD Concern, AWD PID
Data Analysis)
LESSON 3B: Workstations (4WD Concern, Service Publications Navigation 4WD PID Recordings, 4WD
Concern, Service Publications Navigation 2007 AWD), Workstation Review
LESSON 4: Workstations (Service Publications Navigation, Driveshaft Angle Measurement, and Service
Publications Navigation)
Hands-On and Written Evaluations
Intro - 3
September 2007
INTRODUCTION
NOTES:
Intro - 4
September 2007
LESSON ONE
PREREQUISITE REVIEW
LESSON 1
1-1
September 2007
LESSON ONE
PREREQUISITE REVIEW
PREREQUISITE REVIEW
DIRECTIONS: Answer the following questions on manual transmissions, transaxles and clutches. Questions may
be related to theory, operation, diagnosis and service. These will be reviewed in class.
Theory and Operation Questions

1. What types of joints may be found on front and rear driveshafts?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
2. What are some ways that high operating angles can be compensated for on vehicles with a driveshaft?
_______________________________________________________________________________________
_______________________________________________________________________________________
3. Which of the following operating angle combinations would provide the least vibration concerns?
A. Transmission joint = +3 degrees; driveshaft angle = +5 degrees; axle pinion joint = -4 degrees
B. Transmission joint = +1.5 degrees; driveshaft angle = +3 degrees; axle pinion joint = +2 degrees
C. Transmission joint = +6 degrees; driveshaft angle = +3 degrees; axle pinion joint = -4 degrees
D. Transmission joint = 0 degrees; driveshaft angle = 0 degrees; axle pinion joint = 0 degrees
Component
Angles:
Working
Angles:
+1.5
+3.0 +2.0
______
______
4. What factors can affect driveline angles on a vehicle?

_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
1-2
September 2007
LESSON ONE
PREREQUISITE REVIEW
Diagnosis and Service Questions

5. List the three main types of axle assemblies:
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
6. Where is the crush sleeve located on a differential assembly?

_______________________________________________________________________________________
What is the crush sleeves function?
_______________________________________________________________________________________
7. What components allow for differential action during turns?

_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
8. Where can you find the ratio of the vehicles axle?

_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
9. What gears in the differential are used to transfer power from the driveshaft to the differential carrier?
_______________________________________________________________________________________
10. What is the main advantage of a limited slip differential over a conventional differential?
_______________________________________________________________________________________
_______________________________________________________________________________________
11. What are the two spring types that can be found on limited slip differentials and what are their purposes?
_______________________________________________________________________________________
_______________________________________________________________________________________
1-3
September 2007
LESSON ONE
PREREQUISITE REVIEW
12. When do the clutch packs in a limited slip differential become active?
_______________________________________________________________________________________
Differential/Driveline Diagnosis, Measurements, Adjustments

13. List some areas of the vehicle besides the driveline that should be checked as possible noise sources:
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
14. Define the following noise diagnosis terms:

Source: _________________________________________________________________________________
Responder: ______________________________________________________________________________
Transfer Path: ____________________________________________________________________________
15. The illustration below is a single ring gear tooth. Label each part of the gear tooth with its correct term:
________
1-4
September 2007
LESSON ONE
PREREQUISITE REVIEW
16. What can a gear pattern check tell you about the ring and pinion assembly?
_______________________________________________________________________________________
_______________________________________________________________________________________
17. What are the possible causes of excessive ring gear backlash variation?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
18. What customer concerns can be caused by each of the following:
Excess total axle backlash: ________________________________________________________________
Carrier bearings too loose (improper preload): ________________________________________________
_______________________________________________________________________________________
19. Can either of the following components be reused after removal?
Collapsible spacer (crush sleeve): Yes
No
Pinion nut:
No
Yes
20. Why must bearing caps in the differential be marked prior to disassembly?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
1-5
September 2007
LESSON ONE
PREREQUISITE REVIEW
1-6
September 2007
LESSON ONE
WORKSTATIONS
LESSON 1
WORKSTATIONS
Workstation:
Summary:
Students use the Service Information Publications DVD and required special service tools to
assemble a Ford 8.8 in. axle and answer related questions in the worksheet.
assemble a Ford 9.75 in. axle and answer related questions in the worksheet.
1-6
September 2007
LESSON ONE
WORKSTATION 1
WORKSTATION 1
FORD 8.8 IN. AXLE ASSEMBLY ON BENCH
TECH ______
DIRECTIONS: Complete Workstation 1 at the bench workstation, using the Ford aluminum 8.8 in. axle,
available hand tools and special service tools, and Workshop Manual.
SUMMARY: For this activity, you will assemble an aluminum 8.8 in. axle, performing critical measurements and
any necessary inspections required by the Workshop Manual. The instructor must initial each Progress Check.
Follow the 2006 Expedition Workshop Manual, Section 205-03, to assemble the axle or use the appropriate
model year Workshop Manual for the axle/differential you have in class.)
As you perform the assembly procedures, pay attention to the following questions related to key steps.
Note:
All students must be exposed to all four critical steps in the assembly process. Therefore, the instructor
will divide you into groups of three; each student performing a critical step either individually or as a
group. This will be monitored and progress will be indicated by the instructor signing-off at the end of
each critical phase.
Assigne d
Te chnicians
Task
Alum inum 8.8 In.
Iron 9.75 In.
Gauge Tube Reading
Tech A _____
Tech B _____
Tech B _____
Tech C _____
Pinion Preload Rotational Check
Tech A _____
Tech B _____
Tech B _____
Tech C _____
Carrier Shim Selection (Backlash) Tech A _____
Tech B _____
Tech B _____
Tech C _____
Pattern Check
Group _____
Group _____
Gauge Tube Readings

1. If the feeler gauge tool will slide between the bore and pinion bearing cup at any point, what can you
conclude?
_______________________________________________________________________________________
2. What is the rotational torque specification for the simulated bearing preload?
_______________________________________________________________________________________
Define rotational torque.
_______________________________________________________________________________________
_______________________________________________________________________________________
3. To select the pinion shim, set the offset gauge block at what angle?
_______________________________________________________________________________________
4. Inspect drive pinion bearing adjustment shims to ensure they are:
_______________________________________________________________________________________
5. What is the suggested method to determine that the correct drive pinion bearing adjustment shim has been
selected?
_______________________________________________________________________________________
1-7
September 2007
LESSON ONE
WORKSTATION 1
6. What is the shim thickness you selected?

_______________________________________________________________________________________
Progress Check
See your instructor before you move on to the next step. Instructor initials: ___________________________

7. How much torque may be required to initially begin crushing the crush sleeve?
_______________________________________________________________________________________
8. To take rotational torque preload readings while installing the pinion nut, the holding tool must be:
_______________________________________________________________________________________
9. What is the recommended technique for tightening the pinion nut?
_______________________________________________________________________________________
10. What must be done if pinion preload is exceeded?
_______________________________________________________________________________________
Progress Check
Carrier Shim Selection (Backlash)

NOTE: In FWD or RWD applications, the ring gear side of the case is always the LH side.
11. After installing the carrier into the housing, where, and what size nominal shims should be installed?
_______________________________________________________________________________________
12. How do you determine the size of the shim for the other side of the carrier?
_______________________________________________________________________________________
_______________________________________________________________________________________
13. What is the largest preliminary shim you can install on the right side?
_______________________________________________________________________________________
14. What is the process for measuring ring gear backlash?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
1-8
September 2007
LESSON ONE
WORKSTATION 1
15. Define backlash variation, and what is the specification?

_______________________________________________________________________________________
_______________________________________________________________________________________
16. Is the measurement within specifications?
Yes
No
17. If not, what is required to bring the readings within specification?

_______________________________________________________________________________________
_______________________________________________________________________________________
18. After the backlash is within specification, how is the differential bearing preload established?
_______________________________________________________________________________________
Progress Check
NOTE: SEE YOUR INSTRUCTOR BEFORE USING SPREADER. Instructor initials: ________________
19. What is the specification for the distance that the housing may be spread?
_______________________________________________________________________________________
20. What can occur if the case is spread more than specification?
_______________________________________________________________________________________
Progress Check
Pattern Check
(Refer to page 1 - 13 through 1 - 15)
21. What does your pattern indicate?
_______________________________________________________________________________________
22. If an error is indicated in the pattern, what adjustment needs to be made?
_______________________________________________________________________________________
23. Is this a face-mill or a face-hob gear set? _________________________________________________
Progress Check
See your instructor. Instructor initials: ___________________________
Disassemble the axle to the way you found it at the start of this Worksheet.
NOTE: YOU MUST ASK THE INSTRUCTOR FOR A DEMONSTRATION ON HOW TO USE THE
D81L-4220-A (205-D036) DRIVE PINION DIFFERENTIAL CARRIER PULLER, FOR
REMOVING THE PINION BEARINGS.
1-9
September 2007
LESSON ONE
WORKSTATION 2
WORKSTATION 2
FORD 9.75 IN. AXLE ASSEMBLY ON BENCH
TECH ______
DIRECTIONS: Complete Workstation 2 at the bench workstation, using the Ford 9.75 in. axle, available hand
tools and special service tools, and Workshop Manual.
SUMMARY: For this activity, you will assemble a Ford 9.75 in. axle, performing critical measurements and any
necessary inspections required by the Workshop Manual. The instructor must initial each Progress Check.
Follow the 2006 Expedition Workshop Manual, Section 205-02, to assemble the axle or use the appropriate
model year Workshop Manual for the axle/differential you have in class.)
As you perform the assembly procedures, pay attention to the following questions related to key steps.
Note:
All students must be exposed to all four critical steps in the assembly process. Therefore, the instructor
will divided the students into groups of three; each student performing a critical step either individually
or as a group. This will be monitored and progress will be indicated by the instructor signing-off at the
end of each critical phase.
Gauge Tube Readings

1. If the feeler gauge will slide between the bore and pinion bearing cup at any point, what can you conclude?
_______________________________________________________________________________________
2. What is the rotational torque specification for the simulated bearing preload?
_______________________________________________________________________________________
Define rotational torque.
_______________________________________________________________________________________
_______________________________________________________________________________________
3. To select the pinion shim, set the offset gauge block at what angle?
_______________________________________________________________________________________
4. Inspect drive pinion bearing adjustment shims to ensure they are:
_______________________________________________________________________________________
5. What is the suggested method to determine that the correct drive pinion bearing adjustment shim has been
selected?
_______________________________________________________________________________________
6. What is the thickness of the shim you selected?
_______________________________________________________________________________________
Progress Check
1 - 10
September 2007
LESSON ONE
WORKSTATION 2

7. How much torque may be required to initially begin crushing the crush sleeve?
_______________________________________________________________________________________
8. To take rotational torque preload readings while installing the pinion nut, the holding tool must be:
______________________
9. What is the recommended technique for tightening the pinion nut?
_______________________________________________________________________________________
10. What must be done if pinion preload is exceeded?
_______________________________________________________________________________________
Progress Check
Carrier Shim Selection (Backlash)

NOTE: In FWD or RWD applications, the ring gear side of the case is always the LH side.
11. After installing the carrier into the housing, where, and what size nominal shim should be installed?
_______________________________________________________________________________________
12. When installing the left bearing cap and bolts, what must be done to ensure the cup is seated?
_______________________________________________________________________________________
13. How do you determine the size of the shim for the other side of the carrier?
_______________________________________________________________________________________
_______________________________________________________________________________________
14. What is the largest shim you can install on the right side?
_______________________________________________________________________________________
15. Before proceeding to measure ring gear backlash:
_______________________________________________________________________________________
16. What is the process for measuring ring gear backlash?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
1 - 11
September 2007
LESSON ONE
WORKSTATION 2
17. What backlash reading did you obtain?

_______________________________________________________________________________________
18. Into which specification category does your backlash result fall? (Circle one).
Within
Zero
Not Within
19. What shim adjustments are required on each side to bring the readings within specification?
Zero
_______________________________________________________________________________________
_______________________________________________________________________________________
Not Within
_______________________________________________________________________________________
_______________________________________________________________________________________
20. After the backlash is within specifications, how is the differential bearing preload established?
_______________________________________________________________________________________
Progress Check
Pattern Check
(Refer to page 1 - 13 through 1 - 15)
21. What does your pattern indicate?
_______________________________________________________________________________________
22. If an error is indicated in the pattern, what adjustment needs to be made?
_______________________________________________________________________________________
23. Is this a face-mill or a face-hob gear set? _________________________________________________
Progress Check
See your instructor. Instructor initials: ___________________________
Disassemble the axle to the way you found it at the start of this Worksheet.
NOTE: YOU MUST ASK THE INSTRUCTOR FOR A DEMONSTRATION ON HOW TO USE THE
D81L-4220-A (205-D036) DRIVE PINION DIFFERENTIAL CARRIER PULLER, FOR
REMOVING THE PINION BEARINGS.
1 - 12
September 2007
LESSON ONE
WORKSTATION 2
Face-Mill and Face-Hob Differences

There are two types of machining processes used in the manufacture of ring gears. One is face-mill and the other
is face-hob. The two machining processes produce distinctly different shapes of ring gear teeth.
Both gear types have identical terms to define the specific areas of the tooth:
top
bottom
toe (the portion facing the center of the ring)
heel (the portion facing the outer edge of the ring)
The heel of a face-mill ring gear tooth is much taller than the toe. The heel of a face-hob ring gear tooth is equal
in height to the toe.
Face-Mill Gear
Top (High)
Heel
Toe
Root (Low)
Top (High)
Heel
Face-Hob Gear
Toe
Root (Low)
Additionally, the shape and location of the pattern varies substantially between face-mill and face-hob gears. This
difference must be noted and the appropriate gear pattern chart used to obtain the correct diagnosis. Detailed
charts are included on the following two pages.
1 - 13
September 2007
LESSON ONE
WORKSTATION 2
GEARSET PATTERN ANALYSIS

On the Drive Side, the heel is to the left. On the Coast Side, the Heel is to the right. The Toe for each is
toward the center.
Use the following chart to determine the action to take after running a pattern on a gearset.
After determining the type of gearset, use the illustration to provide you with the necessary corrective steps.
5
4
2
3
7
0
8
10
1
10
5
0
8
4
2
3
7
Face-Hob Drive Pattern
Face-Hob Coast Pattern
Central
OK
Central
OK
Central Toe
OK
Central Toe
OK
Central Heel
Possibly lower backlash
Central Heel
Possibly raise backlash
Heel
Lower backlash -- reject if

backlash is already low
Heel
Raise backlash -- reject if

backlash is already high
Heel and High
Add pinion shim,

lower backlash
Heel and High
Add pinion shim
Central High
Add pinion shim
Central High
Add pinion shim
Toe and High
Toe and High
Add pinion shim
Add pinion shim

lower backlash if necessary
Heel and Deep
Subtract pinion shim
Heel and Deep
Central Deep

raise backlash if necessary
Toe
Raise backlash
Central Deep

raise backlash if necessary
Toe
Lower backlash
10 Toe and Deep
Subtract pinion shim,

raise backlash
Face-Mill Drive Pattern
10 Toe and Deep
Central
OK
Central Toe
OK
Central Heel
Possibly lower backlash
Heel
Lower backlash -- reject if backlash is already low
Heel and High
Add pinion shim, lower backlash if it is high
Central High
Add pinion shim
Toe and High
Add pinion shim, raise backlash if necessary
Heel and Deep
Subtract pinion shim and lower backlash if necessary
Central Deep
Toe
Raise backlash
10 Toe and Deep
Subtract pinion shim, raise backlash
1 - 14
September 2007
LESSON ONE
WORKSTATION 2
FACE-MILL GEARSETS
Use the following chart to determine the action to take after running a pattern on a gearset.
After determining the type of gearset, use the illustration to provide you with the necessary corrective steps.
ACTION REQUIRED
COAST
DRIVE
Normal or desirable pattern. The drive

pattern should be centered on the tooth.
The coast pattern should be centered on
the tooth, but may be slightly toward the
toe. There should be some clearance
between the pattern and the
top (heel) of the tooth.
A
Desirable Pattern
Backlash correct.
Thicker pinion position shim required.
B
Top Heel/Top Toe Contact
Backlash correct.
Thinner pinion position shim required.
C
Root Toe (Low)/Root Heel (Low) Contact
Pinion shim correct.
Decrease backlash.
D
Top Heel/Top Heel Contact
Pinion shim correct.
Increase backlash.
E
Root Toe (Low)/Root Toe (Low) Contact
1 - 15
September 2007
LESSON ONE
WORKSTATION 2
FACE HOB
Pinion High
DRIVE SIDE
Heel
CONDITION
Toe
COAST SIDE
Toe
CONDITION
Heel
Root Heel Contact
Root Toe Contact
Normal
CONDITION
DRIVE SIDE
Heel
Toe
COAST SIDE
Toe
CONDITION
Heel
Desirable Pattern.
The coast pattern
should be centered on
the tooth, but may be
slightly toward the toe.
There should be some
clearance between the
pattern and the top of
the tooth.
Desirable Pattern.
The drive pattern
the tooth. There
should be some
the tooth.
Pinion Low
DRIVE SIDE
Heel
CONDITION
Toe
Toe
Top Toe Contact
COAST SIDE
1 - 16
CONDITION
Heel
Top Heel Contact
September 2007
LESSON ONE
WORKSTATION 2
FACE MILL
Pinion High
DRIVE SIDE
Heel
CONDITION
Toe
COAST SIDE
Toe
CONDITION
Heel
Root Toe Contact
Root Heel Contact
Normal
DRIVE SIDE
Heel
CONDITION
Toe
COAST SIDE
Toe
CONDITION
Heel
Desirable pattern.
The coast pattern
the tooth, but may be
slightly toward the toe.
There should be some
pattern and the top
(heel) of the tooth.
Desirable pattern.
The drive pattern
the tooth. There
should be some
the tooth.
Pinion Low
DRIVE SIDE
Heel
CONDITION
Toe
Toe
Top Heel Contact
COAST SIDE
1 - 17
CONDITION
Heel
Top Toe Contact
September 2007
LESSON ONE
WORKSTATION 2
Dana Differential Setup

Pinion Bearing Shim
Dana axles use the same pinion depth setup tools as other Ford axles. The significant difference between a Dana
and a Ford pinion is that the Dana pinion is measured and a correction factor is engraved on the end of the pinion.
This engraved correction number provides a correction factor to help the shimming process.
Notice the plus (+), minus (-) or zero (0) etching on the new drive pinion. Adjust the thickness of the new drive
pinion position shim as follows:
If etching is plus (+), subtract the number from the gauged drive pinion position shim thickness.
If etching is minus (-), add the number to the gauged drive pinion position shim thickness.
There is a metric version that is designated by an m
1 - 18
September 2007
LESSON ONE
WORKSTATION 2
Dana Differential Setup (contd)

Dana Side Bearing Preload
A dial indicator (1) is used along with a set of dummy bearings (2) to measure case endplay. The dummy bearings are a fixed size, used to calculate the size of the shims needed for side bearing preload and backlash.
Dial Indicator
Dummy Bearings
The Workshop Manual has a chart to help you calculate differential side bearing shim thickness that is required.
Line
Ite m
Re sult (actual)
Re sult (e x am ple )
Total endplay reading (without gears)
Add preload
Total (A and B)
2.2352 mm
(0.088 in.)
Endplay measurement (with gears)
1.0414 mm
(0.041 in.)
Subtract the shim thickness on the ring

gear side
Total (Subtract E from D) (thickness of

shims to place on the ring gear side)
0.9652 mm
(0.038 in.)
Total (Subtract F from C) (thickness of

shims to place on the drive pinion side)
1.27 mm
(0.050 in.)
2.032 mm
(0.080 in.)
+0.2032 mm
(+ 0.008 in.)
-0.0762 mm
(-0.003 in.)
1 - 19
+ 0.2032 mm
(+ 0.008 in)
-0.0762 mm
(0.003 in.)
September 2007
LESSON TWO
PREREQUISITE REVIEW
LESSON 2
2-1
September 2007
LESSON TWO
PREREQUISITE REVIEW
PREREQUISITE REVIEW
DIRECTIONS: Answer the following questions on transfer cases and 4WD systems. Questions may be related to
theory, operation, diagnosis and service. These will be reviewed in class.
Transfer Case and 4WD Theory and Operation Questions

1. List as many types of 4WD systems as you can identify:
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
2. What are the basic hublock types available?

_______________________________________________________________________________________
_______________________________________________________________________________________
3. What is the sequence to shift the transfer case from 4H to 4L?

_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
4. Under what driving conditions should you NOT use any 4H or 4L modes?
_______________________________________________________________________________________
5. What component(s) inside the transfer case are used to create 4L mode?
_______________________________________________________________________________________
6. What components are used to transfer power from the rear tail shaft to the front driveshaft within a transfer
case?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
2-2
September 2007
LESSON TWO
PREREQUISITE REVIEW
7. List some of the outputs used in an electronically-controlled A4WD system:

_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
8. List some inputs commonly used in an electronically-controlled A4WD system:

_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
9. What are the maximum mode switch selections that are available?
_______________________________________________________________________________________
What is the function of these switch positions?
_______________________________________________________________________________________
_______________________________________________________________________________________
2-3
September 2007
LESSON TWO
PREREQUISITE REVIEW
AWD Components/Operation
10. What does the acronym DEM stand for, and what is its function?
_______________________________________________________________________________________
_______________________________________________________________________________________
11. What are the four types of AWD systems used in current Ford Motor Company vehicles?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
12. How are front and rear driveshaft speeds monitored in AOC and ATC systems?
_______________________________________________________________________________________
13. In an ATC transfer case, where are the nested ball bearings located?
_______________________________________________________________________________________
14. On the ATC, what is required to directly activate the clutch?

_______________________________________________________________________________________
_______________________________________________________________________________________
15. What diagnostic process is described by the term S-S-C-C?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
2-4
September 2007
LESSON TWO
PREREQUISITE REVIEW
16. Why is it important to verify a customer concern with the 4WD system?
_______________________________________________________________________________________
17. How can you verify 4WD High or Low are operating correctly?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
18. All electrical tests for an IWE hublock system have passed, but you still have a concern. What happens in this
system when vacuum is lost?
_______________________________________________________________________________________
19. How are PVH hubs applied and released?

_______________________________________________________________________________________
20. Where should you continue your 4WD system diagnosis if all electrical checks pass?
_______________________________________________________________________________________
2-5
September 2007
LESSON TWO
PREREQUISITE REVIEW
2-6
September 2007
LESSON TWO
WORKSTATIONS
LESSON 2
WORKSTATIONS
Workstation:
Summary:
disassemble down to the subassemblies, inspect and assemble a Borg-Warner 4406 4WD
Transfer Case and answer related questions in the worksheet.
disassemble down to the subassemblies, inspect and assemble a Borg-Warner 4405 4WD
Transfer Case and answer related questions in the worksheet.
Students use the Service Information Publications DVD and scan tool to navigate through
various 4WD PIDs to answer worksheet questions.
Students use the Service Information Publications DVD and a scan tool to navigate through
various 4WD PIDs to answer worksheet questions.
Differential and 4WD Systems Diagnosis and Repair 2 - 6
September 2007
LESSON TWO
WORKSTATION 1
WORKSTATION 1
4406 TRANSFER CASE DISASSEMBLY AND ASSEMBLY (BENCH)
DIRECTIONS: Complete Workstation 1 at the bench workstation, using the Borg-Warner 4406 4x4 Transfer
Case, available hand tools and special service tools, and Workshop Manual.
SUMMARY: For this activity, you will disassemble, inspect the subassemblies, and assemble a 4406 Transfer
Case, performing any necessary inspections required by the Workshop Manual.
Follow the 2006 F-150 Workshop Manual, Section 308-07B.
As you perform the disassembly and assembly procedures, pay attention to the following questions related to
key steps.
1. How many speed sensors are located on the case? _______________________________________________

Note the following during this procedure:
Do not remove bearings.
Do not remove the seals.
Do not remove the ring gear.
Do not remove the field coil.
DO remove the carrier.
2. Why does the output shaft need to be lifted up? _________________________________________________

3. Why is it normal to find metal shavings once the case separated?
_______________________________________________________________________________________
4. What type of clutch does the unit have internally?
_______________________________________________________________________________________
5. Can the ring gear be removed from the case, and how does it come out? For this activity, DO NOT remove
this component.
_______________________________________________________________________________________
6. Why do you have to remove the input seal?
_______________________________________________________________________________________
7. How many shift forks does this unit have, and what are their purposes?
_______________________________________________________________________________________
_______________________________________________________________________________________
8. As case halves are reassembled, what might happen if too much silicone sealer is used?
_______________________________________________________________________________________
Upon completion of assembly, demonstrate to the instructor that high and low ranges are available using a
spare motor actuator gear.
September 2007
LESSON TWO
WORKSTATION 2
WORKSTATION 2
4405 TRANSFER CASE DISASSEMBLY AND ASSEMBLY (BENCH)
DIRECTIONS: Complete Workstation 2 at the bench workstation, using the Borg-Warner 4405 4x4 Transfer
Case, available hand tools and special service tools and the Workshop Manual.
SUMMARY: For this activity, you will disassemble, inspect the subassemblies, and assemble a 4405 Transfer
Case, performing any necessary inspections required by the Workshop Manual.
Follow the 2006 Explorer Workshop Manual, Section 308-07B. Use the 2-speed transfer case procedures.
key steps.
1. How many speed sensors are located on the case? _______________________________________________

Note the following during this procedure:
Do not remove bearings.
Do not remove the seals.
Do not remove the ring gear.
Do not remove the field coil.
DO remove the carrier.
2. Why doesnt the current model year transfer case use speed sensors?
_______________________________________________________________________________________
_______________________________________________________________________________________
3. Why is it normal to find metal shavings once the case is spread?
_______________________________________________________________________________________
4. When all bolts are removed, how are the case halves separated?
_______________________________________________________________________________________
5. Can the ring gear be removed from the case and how does it come out?
_______________________________________________________________________________________
6. What is the torque specification for the transfer case bolts? ________________________________________
7. How many shift forks does this unit have? What is its function?
_______________________________________________________________________________________
8. How does the clutch operate the chain?
_______________________________________________________________________________________
_______________________________________________________________________________________
Upon completion of assembly, demonstrate to the instructor that high and low ranges are available using a
spare motor actuator gear.
September 2007
LESSON TWO
WORKSTATION 3
WORKSTATION 3
4WD PID NAVIGATION (ON-VEHICLE)
DIRECTIONS: Complete Workstation 3 on-vehicle, using the IDS scan tool, available hand tools, and Workshop
Manual.
SUMMARY: For this activity, you will connect the IDS to the vehicle, navigate through the 4WD PIDs, and
perform any necessary inspections required by the Workshop Manual.
Follow the 2008 Expedition Workshop Manual.
As you complete the worksheet, pay attention to the following questions related to key steps.
1. Perform a self-test on the 4x4 Module. Are any codes present? ____________________________________
2. Exit the self-test and select Datalogger menu. What two menus can be selected to view 4WD PIDs? Are
there any numerical differences in the available PIDs?
_______________________________________________________________________________________
_______________________________________________________________________________________
3. How could this information enhance your diagnostic ability?
_______________________________________________________________________________________
NOTE: Turn off TracAssist before continuing to the next steps.
While in DataLogger, answer the following questions:
4. What is the drivers main input to this system?
_______________________________________________________________________________________
5. What are the main inputs required to command 4L?
_______________________________________________________________________________________
6. What type of 4x4 concern could these PIDs be used to diagnose?
_______________________________________________________________________________________
7. What PID indicates a change in 4x4 mode?
_______________________________________________________________________________________
8. What inputs will cause the 4x4 Torque On Demand relay to energize and create A4WD?
_______________________________________________________________________________________
9. What output(s) is (are) required to create 4L?
_______________________________________________________________________________________
10. How will the module let you know 4L has been achieved?
_______________________________________________________________________________________
_______________________________________________________________________________________
January 2008
LESSON TWO
WORKSTATION 3
11. Select the following PIDs: Mode Select Switch, Clutch Pulse Width Status, Front and Rear Shaft Speeds.
With the engine running, place the transmission gear selector in Drive and release the brakes. Monitor the
above PIDs and transition from A4WD to 4H. What changed?
_______________________________________________________________________________________
_______________________________________________________________________________________
12. Which PID reflects the status of a wheel hub engagement or release command?
_______________________________________________________________________________________
What is the PID status to engage the hub system?
_______________________________________________________________________________________
January 2008
WORKSTATION 4
LESSON TWO
WORKSTATION 4
4WD PID NAVIGATION (ON-VEHICLE)
DIRECTIONS: Complete Workstation 4 on-vehicle, using the IDS scan tool, available hand tools, and Workshop
Manual.
SUMMARY: For this activity, connect the IDS to the vehicle, navigate through the 4WD PIDs, and perform any
necessary inspections required by the Workshop Manual.
Follow the 2008 Ranger Workshop Manual.
1. Perform a self-test on the 4x4 Module. Are any codes present? ____________________________________
2. Exit the self-test and select Datalogger menu. What two menus can be selected to view 4WD PIDs? Are
there any numerical differences in the available PIDs?
_______________________________________________________________________________________
_______________________________________________________________________________________
3. How could this information enhance your diagnostic ability?
_______________________________________________________________________________________
While in DataLogger, answer the following questions:
4. What is the drivers main input to this system?
_______________________________________________________________________________________
5. What are the main inputs required to command 4L?
_______________________________________________________________________________________
6. What type of 4x4 concern could these PIDs be used to diagnose?
_______________________________________________________________________________________
7. What output(s) are required for 4WD?
_______________________________________________________________________________________
8. What do these outputs control?
_______________________________________________________________________________________
9. What inputs tell the module when the motor has achieved the correct status?
_______________________________________________________________________________________
10. Is there an active command PID related to the above question? What is it and what is its purpose?
_______________________________________________________________________________________
January 2008
LESSON TWO
WORKSTATION 4
11. Can the 4x4 indicator lamp be manipulated by any active command/PID?
_______________________________________________________________________________________
12. While in Mode Switch 2WD, select the following plate PIDs: A, B, C, D and PLATE_PWR #, then command
PLATE_PWR # on. Record the values.
Plate PID
MSS PID 2WD
PLAT E_A
PLAT E_B
PLAT E_C
PLAT E_D
13. Shut off Active Command. Select 4H. Command PLATE_PWR back on. Record the values.
Plate PID
MSS PID 4WDH
PLAT E_A
PLAT E_B
PLAT E_C
PLAT E_D
14. Turn the switch from 4H to 2H. Does the transfer case transition?
_______________________________________________________________________________________
15. Exit PLATE_PWR #. Command 2H. Record the values.
Plate PID
MSS PID 2WD
PLAT E_A
PLAT E_B
PLAT E_C
PLAT E_D
September 2007
LESSON TWO
WORKSTATION 4
16. If you did not know that plate PIDs change to an open state after completion of a command, how could this
affect your diagnosis?
_______________________________________________________________________________________
_______________________________________________________________________________________
January 2008
LESSON THREE
WORKSTATIONS
LESSON 3A
WORKSTATIONS
Workstation:
Summary:
1A
disassemble and assemble an 8.8 in. Traction-Lok differential and answer related questions in
the worksheet.
2A
disassemble and assemble a 10.5 in. Traction-Lok differential and answer related questions in
the worksheet.
3A
diagnose a 4WD Concern and answer related questions in the worksheet.
4A
Students will analyze AWD PID data graphs and use the Service Information Publications
DVD to answer worksheet questions.
September 2007
LESSON THREE
WORKSTATION 1A
WORKSTATION 1A
TRACTION-LOK DISASSEMBLY AND ASSEMBLY (BENCH)
DIRECTIONS: Complete Workstation 1A at the bench workstation, using the Ford 8.8 in. axle, available hand
tools and special service tools, and Workshop Manual.
SUMMARY: For this activity, you will disassemble, inspect and assemble a Ford 8.8 in. Traction-Lok axle,
performing any necessary inspections required by the Workshop Manual.
Follow the 2006 Ranger Workshop Manual, Section 205-02B.
key steps.
DISASSEMBLY
1. What should be done with the anti-lock speed sensor ring?
_______________________________________________________________________________________
2. How should you position the differential case when removing the S-Spring to avoid personal injury?
_______________________________________________________________________________________
3. What should be done immediately after removing the clutch packs?
_______________________________________________________________________________________
4. How should clutch packs be cleaned? _________________________________________________________
ASSEMBLY
5. Soak clutch packs in __________________________ for no less than ______ minutes.
6. What is the torque specification for the nut on the Clutch Gauge Special Tool? ________________________
7. What is the thickest feeler gauge blade that will fit between the differential clutch pack and special tool?
_______________________________________________________________________________________
What does this feeler gauge size represent? ____________________________________________________
8. What is recommended for the bolt that holds the differential pin in place?
_______________________________________________________________________________________
_______________________________________________________________________________________
9. What are the breakaway torque specifications for the clutch plates?
Reused clutch plates: _____________________________
September 2007
LESSON THREE
WORKSTATION 2A
WORKSTATION 2A
TRACTION-LOK DISASSEMBLY AND ASSEMBLY (BENCH)
DIRECTIONS: Complete Workstation 2A at the bench workstation, using the Ford 10.5 in. Traction-Lok axle,
available hand tools and special service tools, and Workshop Manual.
SUMMARY: For this activity, you will disassemble, inspect and assemble a Ford 10.5 in. axle, performing any
necessary inspections required by the Workshop Manual.
For the 10.5 in. axle, follow the 2006 F-Super Duty Workshop Manual, Section 205-02D.
key steps.
DISASSEMBLY
1. Before removing the differential case bolts, what important step must be performed?
_______________________________________________________________________________________
2. What do you notice about the Belleville spring? ________________________________________________
ASSEMBLY
3. What should new clutch discs be soaked in prior to Traction-Lok differential assembly?
_______________________________________________________________________________________
4. Why are the Belleville spring and shim left off the clutch pack when gauging?
_______________________________________________________________________________________
5. What is the largest feeler gauge that will fit between the special tool and clutch pack?
_______________________________________________________________________________________
6. How should the Belleville spring be oriented on the clutch pack?
_______________________________________________________________________________________
7. What is the specification for the differential side gear breakaway torque?
_______________________________________________________________________________________
8. If breakaway torque is not within specification (too light), what could be the cause?
_______________________________________________________________________________________
_______________________________________________________________________________________
If breakaway torque is not within specification (too heavy), what could be the cause?
_______________________________________________________________________________________
_______________________________________________________________________________________
September 2007
LESSON THREE
WORKSTATION 3A
WORKSTATION 3A
4WD CONCERN (ON-VEHICLE)
DIRECTIONS: Complete Workstation 2A on the vehicle, using available hand tools and special service tools,
and Workshop Manual.
SUMMARY: For this activity, you will work on a 2008 Expedition with a 4x4 concern, performing any necessary
inspections required by the Workshop Manual.
Follow the 2008 Expedition Workshop Manual, Section 308-07A.
A 2008 Expedition is in your service bay with the following customer concern:
Front Drive Axle Does Not Disengage
1. Which symptom description best matches the customer concern in the Symptom Chart?
_______________________________________________________________________________________
2. What are some of the likely causes of this symptom?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
Continued on next page.
January 2008
LESSON THREE
WORKSTATION 3A
NOTE: In this activity, you will NOT be installing an S-spring in the front differential.
3. What is the next step?
_______________________________________________________________________________________
4. Complete the chart below.
TEST STEP
RESULT
5. List the possible purposes of each step that you performed above:
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
January 2008
LESSON THREE
WORKSTATION 4A
WORKSTATION 4A
AWD PID DATA ANALYSIS (TABLETOP/COMPUTER)
DIRECTIONS: Complete Workstation 3A using the recorded paper snapshots, the Workshop Manual and Wiring
Diagrams.
SUMMARY: For this activity, you will use the AWD PID Data Analysis Graphs located at the workstation and
interpret what is happening with the vehicle to answer the questions in this worksheet.
Follow the 2006 Montego AWD Workshop Manual and Wiring Diagrams.
Graph 1
1. While looking at the Graph 1 data, what can you determine about the operating condition of the vehicle at
minus 13 seconds?
_______________________________________________________________________________________
_______________________________________________________________________________________
2. What is the current oil pressure in the Active On-Demand coupling at minus 13 seconds?
_______________________________________________________________________________________
3. What is the Valve Amperage at this point? _____________________________________________________
Graph 2
approximately minus 0.7 seconds?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
How many active command PIDs are available for this unit, and list them? ___________________________
Graph 3
approximately minus 0.5 seconds? (Be sure to note the value of the line.)
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
6. Why has the oil pressure changed? __________________________________________________________
September 2007
LESSON THREE
WORKSTATION 4A
7. Why has the valve amperage changed?

_______________________________________________________________________________________
Workshop Manual and Wiring Diagram
8. What is the name of the module that controls the AWD system?
_______________________________________________________________________________________
9. What is the number of the fuse protecting this AWD system and where is its location?
_______________________________________________________________________________________
10. What is the terminal pin number at the module that receives power from this fuse?
_______________________________________________________________________________________
11. How many pinpoint tests are available to diagnose the DEM for this AWD system? List them.
_______________________________________________________________________________________
12. What instrument cluster indicator light illuminates when the DEM detects faults in the AWD system?
_______________________________________________________________________________________
13. What are the name and locations of the grounds for the system?
_______________________________________________________________________________________
_______________________________________________________________________________________
14. What are the communication network circuit numbers? ___________________________________________
15. What type of communication network is this?___________________________________________________
September 2007
LESSON THREE
WORKSTATIONS
NOTES:
September 2007
LESSON THREE
WORKSTATIONS
LESSON 3B
WORKSTATIONS
Workstation:
Summary:
1B
Students will diagnose a 4WD concern on an Expedition using the Service Information
Publications DVD to to complete the worksheet.
2B
Students use the Service Information Publications DVD and PID data recordings at the bench
to diagnose a 4WD Expedition concern to complete the worksheet.
3B
Students will use the Service Information Publications DVD and available diagnostic tools to
diagnose an on-vehicle 4WD concern on a Ranger to complete the worksheet.
4B
Students will use the Service Information Publications DVD at the bench to navigate through
an AWD concern on a 2007 Fusion to complete the worksheet.
3-9
September 2007
LESSON THREE
WORKSTATION 1B
WORKSTATION 1B
DIAGNOSE 4WD CONCERN (ON-VEHICLE)
DIRECTIONS: Complete Workstation 1B on a 2008 Expedition using the a scan tool, available hand tools and
special service tools, and Workshop Manual.
SUMMARY: For this activity, you will use Service Information Publication manuals to diagnose an on-vehicle
4WD concern.
Directions: Complete the following worksheet. When you are finished return the workstation to the way you
found it.
Concern: No 4WD operation. There are no TSBs related to this concern.
1. Verify concern.
2. Perform visual inspection.
3. Run On Demand/Continuous self test and record any codes present. Are any codes present?
_______________________________________________________________________________________
4. If so, what are they? _______________________________________________________________________
5. What is the next step? _____________________________________________________________________
NOTE: Answer No to any Pinpoint Test that requires a vehicle road test.
TEST STEP
RESULT
6. What is the root cause of the concern after following Pinpoint Test M?
_______________________________________________________________________________________
7. What further tests could you perform to better determine the cause of the concern?
_______________________________________________________________________________________
8. Perform these tests to determine the exact cause of the failure. What did you find?
_______________________________________________________________________________________
NOTE: Do not make the above repair.

Return the vehicle and workstation to the way you found them.
3 - 10
January 2008
LESSON THREE
WORKSTATION 2B
WORKSTATION 2B
SERVICE PUBLICATIONS NAVIGATION
4WD PID RECORDINGS (TABLETOP/COMPUTER)
DIRECTIONS: Complete Workstation 2B at a desk computer, using a Workshop Manual. To locate the
recordings on the computer:
1. Open the WDS/IDS Desk Top Mode icon on the computer desktop.
2. Select Previous Sessions and click the blue Continue checkmark.
3. Select 6LA70024 Expedition 5.4L and click the blue Continue checkmark.
4. Click on Toolbox tab.
5. Select Datalogger and click the blue Continue checkmark.
6. Select the first recording and click the blue Continue checkmark.
SUMMARY: For this activity, you will use service information publications to diagnose a 4WD concern.
Capture Event 8
1. While looking at the Capture Event 8 data, what can you determine about the operating condition of the
vehicle at minus 10 seconds?
_______________________________________________________________________________________
2. What can you determine from the operating condition of the vehicle at minus 5 seconds?
_______________________________________________________________________________________
3. What is the 4WD Controller PWM state reaction at this point? _____________________________________
4. What can you determine about the operating condition of the vehicle based on the information provided in
Capture Event 8? ________________________________________________________________________
Capture Event 9
5. Compared to Capture Event #8 above, what can you determine about the operating condition of the vehicle at
+7 seconds? (Be sure to note the value of the line.)
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
6. Why are the readings in Capture Event 9 occurring?
_______________________________________________________________________________________
_______________________________________________________________________________________
7. What components could possibly be causing the readings in Capture Event 9?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
3 - 11
September 2007
LESSON THREE
WORKSTATION 3B
WORKSTATION 3B
DIAGNOSE 4WD CONCERN (ON-VEHICLE)
DIRECTIONS: Complete Workstation 3B on-vehicle, using a scan tool, available hand tools, and Workshop
Manual.
SUMMARY: For this activity, you will use the scan tool, navigate the menus, and perform any necessary
inspections required by the Workshop Manual.
Follow the 2008 Ranger Workshop Manual.
Directions: Complete the following worksheet. When you are finished, return the workstation to the
way you found it.
Concern: No 4WD operation. There are no TSBs related to this concern.
1. Verify concern.
2. Perform visual inspection.
3. Perform a self-test. Are any codes present? ____________________________________________________
4. What is the next step? _____________________________________________________________________
5. Perform the diagnostic steps in the Workshop Manual and record in the table below.
NOTE: If, while performing the diagnostics you are asked if you performed the Electronic Shift Functional Test,
assume that you have and answer yes. Then continue your diagnosis as directed.
TEST STEP
RESULT
6. What is the root cause of the concern? ________________________________________________________

7. What is the recommended repair? ____________________________________________________________
NOTE: Do not make the above repair.

Return the vehicle and workstation to the way you found them.
3 - 12
January 2008
LESSON THREE
WORKSTATION 4B
WORKSTATION 4B
SERVICE PUBLICATIONS NAVIGATION - 2007 AWD FUSION (TABLETOP/COMPUTER)
DIRECTIONS: Complete Workstation 4B using a desktop computer and Workshop Manual.
SUMMARY: For this activity, you will use the Workshop Manual to answer the following questions.
Follow the 2007 Fusion Workshop Manual.
Directions: Complete the following worksheet.

1. What module in a 2007 Fusion AWD generates DTC P1635? _____________________________________
2. What is the actual symptom description for this DTC, and the Pinpoint Test that should be followed?
_______________________________________________________________________________________
3. What are some of the likely causes that this Pinpoint Test suggests?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
4. What are the first three Pinpoint Tests asking you to check?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
5. What is the next check? ____________________________________
6. If one wheel speed sensor is off by 2 mph, what do you do?
_______________________________________________________________________________________
7. What are the preliminary steps you need to do first?
_______________________________________________________________________________________
_______________________________________________________________________________________
8. Assume all initial checks pass with no ABS DTCs. Where do you go next? __________________________
9. What is the most likely cause for this condition?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
10. An AWD unit has been overheated and has entered locked mode. What do you do next?
_______________________________________________________________________________________
_______________________________________________________________________________________
3 - 13
September 2007
LESSON THREE
WORKSTATIONS
NOTES:
3 - 14
September 2007
LESSON FOUR
WORKSTATIONS
LESSON 4
WORKSTATIONS
Workstation:
Summary:
a 4WD system concern on a Ranger.
Students will use the Service Information Publications DVD to perform driveline angle
measurements on a vehicle using the required tools.
a 4WD system concern on a Ranger.
4-1
September 2007
LESSON FOUR
WORKSTATION 1
WORKSTATION 1
SERVICE PUBLICATIONS NAVIGATION 2006 4WD RANGER
(TABLETOP/COMPUTER)
DIRECTIONS: Complete Workstation 1 at a desktop computer using the Service Information Publications
DVD.
SUMMARY: For this activity, you will navigate a 2006 Ranger Workshop Manual and Wiring Diagram. As you
complete the worksheet, pay attention to the following questions related to key steps.
1. The Workshop Manual specifies what type, weight, and amount of oil to use in the transfer case?
_______________________________________________________________________________________
2. In the symptom chart for 4WD systems, how many concerns are listed? _______________________
3. If the 4WD indicators are always on with normal 4WD operation, what section of the Workshop Manual are
you directed to go to, and what are you checking within that section?
_______________________________________________________________________________________
4. What do pinpoint Tests S9 and S10 have in common?
_______________________________________________________________________________________
5. Referring to the wiring diagrams, what type of module controls the 4WD system of the Ranger?
_______________________________________________________________________________________
6. Where is the 4WD control module located on this vehicle?
_______________________________________________________________________________________
7. According to the DTC chart in the service publications, what does DTC P1812 indicate?
_______________________________________________________________________________________
8. According to Wiring Diagrams, what circuit(s) are used to connect with an IDS during diagnostic procedures?
_______________________________________________________________________________________
9. If a DTC is retrieved that is not on the 4WD Control Module DTC Index, where are you directed to according
to the steps listed under Inspection and Verification?
_______________________________________________________________________________________
What is being tested by the above Pinpoint Test?
_______________________________________________________________________________________
10. If DTC P1707 is retrieved, what action does the DTC Index direct you to take?
_______________________________________________________________________________________
Describe the normal operation of the system in this test.
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
4-2
September 2007
LESSON FOUR
WORKSTATION 2
WORKSTATION 2
DRIVESHAFT ANGLE MEASUREMENT (ON-VEHICLE)
DIRECTIONS: Complete Workstation 2 using available hand tools, special tools and Workshop Manual.
SUMMARY: For this activity, you will describe the procedure for a driveshaft angle adjustment on a vehicle, and
then perform a driveshaft angle measurement.
Follow the 2008 Expedition Workshop Manual.
Instructions: Using the Service Information Publications DVD answer the questions below.
1. What is the procedure for measuring driveshaft angle on this vehicle after the preliminary setup steps have
been performed?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
2. Refer to the chart in the WSM. List the specification for this measurement, your actual reading, and whether
the actual reading is in or out of specifications.
Transmission Yoke Angle:
_________________
Driveshaft Angle:
Pinion Yoke Angle:
_________________
Specification:
__________________
_____________________________
3. What is the rule when two connected components slope in the same direction?
_______________________________________________________________________________________
4. What is the rule when two connected components slope in the opposite direction?
_______________________________________________________________________________________
5. What are the ideal operating angles?
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
4-3
January 2008
LESSON FOUR
WORKSTATION 3
WORKSTATION 3
SERVICE PUBLICATIONS NAVIGATION 1999 4WD RANGER
(TABLETOP/COMPUTER)
DIRECTIONS: Complete Workstation 3 at a desktop computer using the Service Information Publications DVD.
SUMMARY: For this activity, you will describe the procedure for diagnosing the concern, Vehicle gets stuck in
mud or snow easily even when 4WD High or Low is commanded. Perform the diagnosis for this vehicle using
1999 Ranger Workshop Manual information. Compare the service publications pinpoint test steps to the pinpoint
steps listed on NEXT PAGE.
The RESULTS COLUMN of the table lists the results of the tests performed, use these results to select the
next step that must be performed.
Continue doing this until youve identified the cause of the concern.
NOTE: SOME STEPS IN THE DATA TABLE ARE NOT USED IN THE DIAGNOSIS AND ARE ONLY
INCLUDED AS DISTRACTORS. Select only the steps that are required.
Write the steps in the spaces provided below in the order you would perform them. As you complete the
worksheet, pay attention to the following questions related to key steps.
No problems were located in OASIS and all TSBs that were researched.
TEST STEP
RESULT
1. What is your diagnosis using the Workshop Manual?

_______________________________________________________________________________________
2. Using the S-S-C-C diagnostic strategy, what do you think are some possible causes of this symptom?
_______________________________________________________________________________________
4-4
September 2007
LESSON FOUR
WORKSTATION 3
DATA SHEET
TEST STEP
RESULT
PPT E9
Vacuum check results are 6 in./Hg received after 6 seconds, then after
20 seconds went to 0 in./Hg.
Go to PPT E1
Held Vacuum at 20 in/Hg for 30 seconds.
Install scan tool and perform DATA

LINK T EST
System Pass.
PPT E8
Vacuum went to 18 in./Hg after 6 seconds and after 15 seconds went

to 0 in./Hg.
PPT E10
Go to ABS Diagnosis Pinpoint Test C
PPT A2
Allow system to release 8 in/hg. after 20 seconds
PPT E18
Resistance is less than 5 ohms
PPT E22
Vacuum drop exceeds 0.5 in/Hg. in 30 seconds
Visual Check
All OK. Radar detector and C.B. radio seem to be improperly installed.
Vehicle is excessively muddy and appears to lack proper
maintenance.
PPT E 7
Vacuum stays below 1 in./Hg during test.
Go to Symptom Chart
Look for condition: Pulse Vacuum Hubs (PVH) operating improperly.
Verify Symptom
Concern exists as stated by the customer/hublocks do not engage

(Transfer case motor movement and front driveshaft operate properly
and halfshafts rotate but hubs do not)
PPT E 2
Held Vacuum at 20 in./Hg for 30 seconds.
PPT E17
Resistance is greater than 10,000 ohms
PPT E 15
Voltage on Circuit C185-2, Circuit 298 and PVH solenoid C185-3 is

present for more than three seconds
PPT E11
Voltage to PVH solenoid is > 10 volts
Record DT Cs and do Self Test
All Pass, No Codes
PP T E 5
With engine running it reads 18 in./Hg.
4-5
September 2007
LESSON FOUR
WORKSTATIONS
NOTES:
4-6
September 2007

36S17T0 Diff - 4WD Diagnosis and Repair - REF

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What is the purpose of notes, cautions, and warnings mentioned in the document?

What is the purpose of notes, cautions, and warnings mentioned in the document?

What are some general safety warnings mentioned for working on a vehicle?

What are some general safety warnings mentioned for working on a vehicle?

Differential and

36 - Manual Transmission & Drivetrain

Ford Customer Service Division

IMPORTANT SAFETY NOTICE

To help prevent serious burns, avoid contact with hot

Copyright 2007 Ford Motor Company

Produced and Coodinated by

Customer Expectations: Service

1. Make it convenient to have my vehicle

2. The Service Advisor should demonstrate

3. Fix it right the first time, on time.

5. Provide me with a clear and thorough

6. Call me within a reasonable amount of

7. Be responsive to questions or concerns

DIFFERENTIAL AND 4WD SYSTEMS DIAGNOSIS AND REPAIR

IINTRODUCTION .............................................................................................. INTRO - 1

LESSON 1 WORKSTATIONS .................................................................................... 1 - 6

LESSON 2 WORKSTATIONS .................................................................................... 2 - 6

4406 Disassembly and Assembly ........................................................................ 2 - 7

LESSON 3A WORKSTATIONS ................................................................................. 3 - 1

LESSON 3B WORKSTATIONS ................................................................................. 3 - 9

4WD Concern ................................................................................................... 3 - 10

Differential and 4WD Systems Diagnosis and Repair

DIFFERENTIAL AND 4WD SYSTEMS DIAGNOSIS AND REPAIR

Differential and 4WD Systems Diagnosis and Repair

DIFFERENTIAL AND 4WD SYSTEMS DIAGNOSIS AND REPAIR

Differential and 4WD Systems Diagnosis and Repair

DIFFERENTIAL AND 4WD SYSTEMS DIAGNOSIS AND REPAIR

DIFFERENTIAL AND 4WD SYSTEMS DIAGNOSIS AND REPAIR

Rear Axle (Left) and Transfer Case (Right)

Differential and 4WD Systems Diagnosis and Repair

DIFFERENTIAL AND 4WD SYSTEMS DIAGNOSIS AND REPAIR

pinion gear shim selection

gear pattern evaluation

service publications navigation

selected special tool usage

4WD On-Vehicle Diagnosis

identify axle/differential and driveline diagnostic procedures.

perform selected driveshaft diagnostic procedures.

identify key axle and differential service procedures.

perform selected axle and differential service procedures.

perform RWD-based 4WD transfer case service procedures.

Hands-On and Written Evaluations

Differential and 4WD Systems Diagnosis and Repair

DIFFERENTIAL AND 4WD SYSTEMS DIAGNOSIS AND REPAIR

Differential and 4WD Systems Diagnosis and Repair

Differential and 4WD Systems Diagnosis and Repair

Theory and Operation Questions

4. What factors can affect driveline angles on a vehicle?

Differential and 4WD Systems Diagnosis and Repair

Diagnosis and Service Questions

6. Where is the crush sleeve located on a differential assembly?

7. What components allow for differential action during turns?

8. Where can you find the ratio of the vehicles axle?

Differential and 4WD Systems Diagnosis and Repair