4x4 not engaging

[Evilpuppetmaster]

Hi Guys,
My first post here.
I have 2003 XLt FX4 Ranger and my 4x4 is not engaging.
when switching to eather 4 HI or 4 Low 4x4 control module will click 4 or 5 times and then stop. after a minute or two it will start clicking again but it will not engage 4x4. When starting the vehicle 4L and 4H lights come on for a second or two and then go off

Now, i have changed 4x4 control module (got it from junkyard) and it did the same thing. 4-5 clicks and stays in 2D.

I have also removed the switch and checked resistors value and they appeared to be OK.

Now for the finall repair, I have dissasembled tc shift motor checked the brushes and applied 12 volts to it just to check if it turns. It did.
What i could not do, was to check position of the sensors on the motor. It is 1 peace and can not be open.

I am open for any suggestions. Lets get her done

[wizkid00104]

I had the same problem with my 94. I disassembled the transfer case motor a few times, cleaned it, regreased it, and it would buy me a little time. To be honest, I wound up swapping in a mechanical shift 1354 from an Exploder in. Imho, that is the only way to truly solve the problem. After swapping, I have had 4x4 everytime I needed it.

If you consider doing the swap, I believe you will need the transfer case from 2002 FX4 or a 2003 FX4 Level 2 with the manual transmission (they were the only mechanical transfer case models.) I believe in 98 the output shaft on the transmission changed which is why there is such limited selection.

Someone else here may know how to fix it. The knowledge on this website seems damn near infinite. But my vote would be for the swap. Mechanical shift cases work very well!

Best of luck!

[Evilpuppetmaster]

Originally Posted by wizkid00104

I had the same problem with my 94. I disassembled the transfer case motor a few times, cleaned it, regreased it, and it would buy me a little time. To be honest, I wound up swapping in a mechanical shift 1354 from an Exploder in. Imho, that is the only way to truly solve the problem. After swapping, I have had 4x4 everytime I needed it.

If you consider doing the swap, I believe you will need the transfer case from 2002 FX4 or a 2003 FX4 Level 2 with the manual transmission (they were the only mechanical transfer case models.) I believe in 98 the output shaft on the transmission changed which is why there is such limited selection.

Someone else here may know how to fix it. The knowledge on this website seems damn near infinite. But my vote would be for the swap. Mechanical shift cases work very well!

Best of luck!

thanks.
i dont consider doing the swap right now.
I just finished opening the position sensor in the motor and it was fine. It seams that motor is not getting power from the module.
Can someone tell me resistor values in the 4x4 switch. I'll re-check them one more time.
What else can it be???

[06RangerXLT]

is the plastic washer on the stop pin flat one one side? They are known for going past where they are supposed to stop, and getting confused. its a simple plastic ring that is designed to tell the motor when it reaches a certain point. pretty sure yours has one. ill see if i can find more infor on it. havent seen any info in a year or so.

[06RangerXLT]

noob question. are you doing it in neutral? it wont shift in a gear unless for manual, the clutch is in, or auto, its in neutral.

[Evilpuppetmaster]

Originally Posted by 06RangerXLT

noob question. are you doing it in neutral? it wont shift in a gear unless for manual, the clutch is in, or auto, its in neutral.

Hi
I have manual transmission and i am testing it in neutral.
This motor does have one black washer and its complete. I will see if i can take a picture of it and post.
Thanks for your help
Alex

[wizkid00104]

Just another thought...

If the transfer case hasn't been used a lot, shifting into gear may require more effort than the shift motor can exert. Perhaps the clicking is the motor overload trip (like you'd hear on a refrigerator for example when the compressor shits the bed). I'd get another opinion to back the idea, but maybe try rotating the shaft on the transfer case to see if you can get it into 4x4.

One more thing. You truck has vacuum actuated hubs. I believe those also need to engage for the 4x4 light to turn on. Maybe the problem is in the hubs and the truck thinks its the transfer case. Just a thought. Best of luck.

[triumphrider-1]

Originally Posted by wizkid00104

One more thing. You truck has vacuum actuated hubs. I believe those also need to engage for the 4x4 light to turn on. Maybe the problem is in the hubs and the truck thinks its the transfer case. Just a thought. Best of luck.

His truck is a live axle, vacuum operation stopped mid-'00.

OP:
Have you tried moving after selecting 4 Hi, or Lo?

Edit:

Originally Posted by Evilpuppetmaster

I just finished opening the position sensor in the motor and it was fine. It seams that motor is not getting power from the module.
Can someone tell me resistor values in the 4x4 switch. I'll re-check them one more time.
What else can it be???

I need to double check the wiring schematic but, if you hear clicking in the 4x4 module that would lead me to believe that switch to be ok. I would say its in the module if you have no voltage to the motor.

[Evilpuppetmaster]

Originally Posted by triumphrider-1

His truck is a live axle, vacuum operation stopped mid-'00.

OP:
Have you tried moving after selecting 4 Hi, or Lo?

Edit:


I need to double check the wiring schematic but, if you hear clicking in the 4x4 module that would lead me to believe that switch to be ok. I would say its in the module if you have no voltage to the motor.

Mistery solved finally....
It was a coroded wire on the main fuse. (fuse # 13 )
i tested this fuse and it was ok but it did not have positive 12 volts due to the coroded wire...

You have all been great help. I owe you few

Now to my next issue (rear door stuck shut)
I'll open another thread.
Cheers
Alex

[wizkid00104]

Congrats!