4WD Lo? Yes. 4WD Hi? No...

[hoohah797]

I used the search function, but I didn't see anything like what I'm experiencing. I have a 2001 Ranger V6 4.0. When I attempt to shift from 2HI to 4HI, it is sporadic. Once in a blue moon it will go in, but most of the time the CM clicks a number of times, the 4WD light flashes then goes out. I have tried shifting into 4HI at a stop, moving, in reverse, clutch in/clutch out and still experience the problem. Now for the confusing part; it will shift in and out of 4LO with no problems at all. When I shift from 4LO to 4HI, again, no problems. Does this sound like its time for a new CM? The shift motor appears to be functioning since it goes in and out of 4LO with no problems. Thanks for any help you can give!

 

[06RangerXLT]

its the electric motor, they use a plastic washer as a stop kind of sensor, and over time the washer develops a flat side, giving the sensor in the motor a wrong reading. basically if you replace that washer thing, (its semi clear and plastic) your problems should be solved. theres a write up on it here somewhere. its pretty easy to do, but the motor is on the T case. so its time consuming.

 

[xkotyx]

when you take the motor apart, MAKE SURE you mark how EVERYTHING comes apart so when you put it together, you will know exactly how to line up. its sensative, so you cant be off by even a tooth.

otherwise you may spend hours trying to line it back up perfectly

 

[koda6966]

Thats odd.. usually it's the other way around with 4lo going before high. At least that's how my brothers 01 is.

 

[hoohah797]

Gotchya. Found the rebuild page on explorerforum.com Is there a part number for the washer? Maybe someone has a link to a replacement?

 

[xkotyx]

Gotchya. Found the rebuild page on explorerforum.com Is there a part number for the washer? Maybe someone has a link to a replacement?

get a thick piece of small hose, cut a piece off and slip it over. poor man fix.

 

[xkotyx]

Thats odd.. usually it's the other way around with 4lo going before high. At least that's how my brothers 01 is.

same with my 91. plus the motor AND the module were out when i got mine.

 

[hoohah797]

Poor man fix or smart man fix? Hmmm

 

[06RangerXLT]

Gotchya. Found the rebuild page on explorerforum.com Is there a part number for the washer? Maybe someone has a link to a replacement?

just turn the washer around so the flat side is 90 degrees from where it was when you pulled it out.

 

[JimJa1943]

That servo motor is pricey. Working on it yourself is the thing to do first.

The small electric motor drives a worm gear. There are electrical contacts on the DRIVEN gear and "fingers" on the cover plate. Sometimes these get dirty enough to lose contact with the electrical contacts they touch. Try cleaning them up first. That could cure your problem. To ensure a good contact between the fingers and their mating surface, you might want to "spring" them out a little IOT increase contact pressure. Contact can also be improved by rubbing a pencil eraser against them. The abrasiveness of the eraser is just enough and won't damage the contacts.

The next step is to take apart the servo motor and clean it up. They are not designed to be taken apart once assembled so the outer shell must have the tabs on either end bent out to get it apart. Like someone else said - mark everything to keep from messing it up when putting it back together.

The copper contacts (the brushes rub against these) can get VERY dirty and lose the ability to make a good contact. Clean them up good (carb cleaner like Chem-12 works well) and reassemble.

Take your time and be careful. It's not difficult, but will take at least 3-4 hours unless you are a natural. That will cure about 90% of all servo motor problems.

On-line, the servo/gear assembly can be had for about $95 shipped, the dealer wants $190 for an OEM unit plus installation. Mine was replaced under warranty and I tried to get the old one. The dealer is a personal friend and would have given it to me, but this time Ford wanted back. I was going to rebuild it myself and keep it for a spare. O'Well. Seems they all go bad at some point.

 

[xkotyx]

just turn the washer around so the flat side is 90 degrees from where it was when you pulled it out.

unless the washer has dried out and broken. when i took my original apart, it was in about 4 pieces.

 

[xkotyx]

Poor man fix or smart man fix? Hmmm

its not gonna hurt it, and it works just the same. just cheaper to go to a hardware store and get a half an inch of hose, than to order that washer.

 

[hoohah797]

CASE CLOSED!

Took TC motor off, disassembled. Looked similar to the pics i found, but not exactly. Not sure if this was because of the model difference between years or what. My motor was a Doorman, not sure if that's what Ford was sticking on them. Couldn't get to the electrical connections or little white washer, again not sure if it was just me missing something or if I was trying to conquer a different beast.

Anyway, went to the local Advance Auto, returned a water pump from a restore project dad and I abandoned, traded in my motor for the core charge, and walked out with a Remaned Borg Warner for $20. Came home bolted it up and plugged her in. Works great every time.

Thanks guys for keeping me from blowing $120 on a computer!!!!

 

[xkotyx]

CASE CLOSED!

Took TC motor off, disassembled. Looked similar to the pics i found, but not exactly. Not sure if this was because of the model difference between years or what. My motor was a Doorman, not sure if that's what Ford was sticking on them. Couldn't get to the electrical connections or little white washer, again not sure if it was just me missing something or if I was trying to conquer a different beast.

Anyway, went to the local Advance Auto, returned a water pump from a restore project dad and I abandoned, traded in my motor for the core charge, and walked out with a Remaned Borg Warner for $20. Came home bolted it up and plugged her in. Works great every time.

Thanks guys for keeping me from blowing $120 on a computer!!!!

wow! $20? cant beat that!!!