Thanks so much for the writeup on the '94 and older transfer case diagnosis. It made my week. I have a '93 ext cab 4x4 with a 3L.
It made complete sense to me as I have been a mechanic, and you saved me bundles in time and money. My problem, it turned out, was in the constant power feed to the 4wd shift controller. Fuses were good. When I checked power at the controller pigtail, I had nothing. So I jumpered a temporary wire from the fuse to the pigtail and I was able to get the module to selftest.
The hard part was trying to determine where the break in the wire was. I pulled up the carpet and right away I saw green coming from one of the wire harnesses. I cut out about a foot of the wire and heat-shrink butt-connected a replacement section due to all of the corrosion in that wire. I think that over years of having tool boxes and kids going in and out on the driver's side had taken their toll on the harness. Thank you!
It made complete sense to me as I have been a mechanic, and you saved me bundles in time and money. My problem, it turned out, was in the constant power feed to the 4wd shift controller. Fuses were good. When I checked power at the controller pigtail, I had nothing. So I jumpered a temporary wire from the fuse to the pigtail and I was able to get the module to selftest.
The hard part was trying to determine where the break in the wire was. I pulled up the carpet and right away I saw green coming from one of the wire harnesses. I cut out about a foot of the wire and heat-shrink butt-connected a replacement section due to all of the corrosion in that wire. I think that over years of having tool boxes and kids going in and out on the driver's side had taken their toll on the harness. Thank you!