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Using 4WL


PaulZ

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99 4.0 5 speed. Any tips on engaging 4WL? Goes from 2w to 4wh quickly but 4wl erratic. Stop, neutral, back up, restart?
 


Robertmangrum.rm

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On my 98. You had to be at a complete stop and shifted into N for it to engage or disengage. Been a while but that's what I remember. It was an auto though.
 

PaulZ

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Thanks Robert. Yes from looking at the little motor that turns the worm gear, my guess is it needs as little load on it as possible.
 

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The manual used to say you had to be at a dead stop, trans in neutral, brake applied before the low range shift will happen and the same when shifting back to high range.
 

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Fold down the the drivers side Sun Visor, usually has a label for that years 4low engagement

Manual trans doesn't have a "neutral switch", clutch pedal down is Neutral
Automatic does have a Neutral switch

Foot on the brake pedal is usually required as well and 0mph

You can get owners manuals here: https://www.therangerstation.com/manuals/

It will also have the 4low instructions
 

PaulZ

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Hey Ron!

Nothing on the visor, just airbag junk. Well I drove it around town today. After sitting an hour it went right into 4WL and back out. An hour later after driving one mile it wouldn’t go into low until I went back and forth down the street a couple times. Neutral and brake on of course. Came home and an hour later went into low and out almost immediately without moving. Of course I don’t need it unless at my cabin on the woods.. Frustrating.

Just noticed on a thread about the contacts inside the round plastic cover by the motor. Never messed with mine, left that all together when I cleaned the motor brushes. Should I have a look at that?

Anybody ever make a manual conversion kit with a lever to bypass all the electrics?

paul
 

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The contact plate and contacts "tell" the 4x4 controller what position the transfer case's shift rod is in, 2H, 4H or 4L
When key is on the controller "knows" the position
If it doesn't then 4WD lights on dash will flash
The contacts also run the dash 4WD lights, i.e. the 4high light won't come on until the shift motor has moved and the contacts show 4H

You can turn the key off then change selector to 4high(was in 2WD) then turn the key on again, and 4x4 controller will see Selector has been changed and will then move transfer case to 4H

001 transfer_case_shift_motor_pin_readings.png


Pin 8 wire(top) is the reference wire, the other 4 wires are either connected to it(short), or not connected to it(open)
And FYI "4H-4L" is Neutral

4x4 controller activates shift motor and "watches" as the contacts open and close then stops the shift motor when contacts Match correct position
If at anytime the contacts are not changing after shift motor is activated 4x4 controller shuts off shift motor and flashes 4WD lights

Yes, they do make custom conversion kit, but expensive, $895: https://www.behemothdrivetrain.com/products/borg-warner-electric-to-manual-shift-conversion-kit

Problem is you have rotate the shift rod 270deg, 2H to 4L and then back, so mechanically its not an easy conversion
 
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PaulZ

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Thanks again Ron,

Well I spent the day running around town, shifting the 4wd back and forth. Worked perfectly, even 4WL. I’d like to think all that movement cleaned up the contacts etc. but we’ll see at the cabin Monday. Usually only fails when needed.

expensive manual kit all right. Except when I’m stuck out there, wife, dog, food, clothing etc. stuck in the stuck truck, I’d probably fish out the cash then!
 

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Are you running it in 4wd on pavement?
 

PaulZ

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Yes just for testing.
 

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I have been lurking around the forum for over a month trying to shift into 4low, it shifts into 4 high but not low, could the sensor plate on the shift motor be bad and still shift to 4high? I have replaced everything else, the brake switch, the speed sensor on transmission, the control module, I assumed that since it shifted to 4high that meant my shift motor was ok, but now I am wondering, did i miss something, I can’t think of what else to waste money on?
 

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I have been lurking around the forum for over a month trying to shift into 4low, it shifts into 4 high but not low, could the sensor plate on the shift motor be bad and still shift to 4high? I have replaced everything else, the brake switch, the speed sensor on transmission, the control module, I assumed that since it shifted to 4high that meant my shift motor was ok, but now I am wondering, did i miss something, I can’t think of what else to waste money on?
What are you doing when trying to shift it into 4 low?
 

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I have been lurking around the forum for over a month trying to shift into 4low, it shifts into 4 high but not low, could the sensor plate on the shift motor be bad and still shift to 4high? I have replaced everything else, the brake switch, the speed sensor on transmission, the control module, I assumed that since it shifted to 4high that meant my shift motor was ok, but now I am wondering, did i miss something, I can’t think of what else to waste money on?
4 low with a manual transmission, you need to be at a full stop with the clutch in or it won't shift. That is for going into and out of 4 low. It also shifts slower than going into and out of 4 high. It takes a little over a second to switch in and out. If it still doesn't shift, I would start looking at the wires and see if anything is damaged. Since it shifts in and out of 4 high, I can't see the motor being bad. Though there might be an issue with the contacts being dirty and maybe needing cleaned.
 

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