1992 4wd module issue

[haydnmiller]

hello, I have 1992 ranger stx. I have had troubles with the 4wd. first it was the module which I replaced, then it was the hubs which i replaced. All was working fine until now. I am not sure what is going on, it could be the t-case shift motor or just the module again, because water sometimes slips through the back glass and gets on the module. The module will make a ticking noise when I try to engage the 4wd like normal, and the t-case shift motor will make a noise and vibration. when I press the test button on the module the red LED does nothing. That is why I am confused.

I have jacked it up and tested to see if the front drive shaft would spin, and that did nothing, but the hubs do work

If you can think of any diagnosis I would greatly appriciate it. Otherwise I might just invest in another 4wd module.

Thanks

 

[haydnmiller]

so, I put in a new 4wd module, and the test light functioned properly on this one. Unfortunately, the 4wd still won't engage.

this leads me to believe that something is wrong with the transfer case.

I will probably take a look at the tcase shift motor, and be back with an update.

"Servicing A Transfer Case Shift Motor" By Craig T. Evers (helpful if you want to service your tcase shift motor)

www.therangerstation.com/tech_library/TCaseshiftmotor.htm

 

[haydnmiller]

Took off the 4wd electric shift motor. It works with no load applied to it, but with any resistance the motor just vibrates and makes a noise like before unable to apply any force.

Next I opened up the motor. mechanically it appeared to be undamaged but needed some lubrication. So, I cleaned up the dried up grease, and applied some white lithium grease.

I put the motor back on and pressed the 4wd high button after a second of rapid clicking noises the t-case shifted into 4 high. I attempted to shift out of 4wd, but nothing happened.

When I try to move move nothing happens. I think the tcase is stuck in a neutral position because the neither the front or rear shafts are getting power, and I can hear what sounds like gear noise. additionally when I am on the clutch, the 4wd shift module clicks once every second accompanied by a flicker of the orange 4wd light on the dash.

I am going to remove the motor again to clock the tcase back to 2wd so i can hopefully drive the darn thing.

I am determined to fix this, so I'll be back with an update (and maybe some pictures) soon.

 

[haydnmiller]

I attached some pictures of the motor, and where it attaches to the t-case.
The transfer case was in a neutral position when I took the motor off again as seen in the 2nd picture.

finally I slapped on a re-manufactured motor, and the 4wd works!