4x4 not disengaging

[guyakaguy]

Hi everyone!

I just bought a 1996 Ranger XLT super cab 4x4 with a 4.0 and an auto.

The guy I bought it from told me that the 4x4 worked, but that it wouldn't disengage so he just unplugged the switch next to the radio. He also told me that it had a "new" shift motor (I know, I know).

Well, last night in my neck of the woods, we got about an inch of snow. I went home for lunch and when I went back to work I couldn't even get the truck back into the driveway for the parking lot (which is ridiculously steep)...

Me, being a dummy and having also never had an electric shift 4x4 before, backed up, pulled the trim panel off, plugged the switch back in, and flipped the switch. For some reason I also flipped the switch all the way to the right into 4LOW... It went in just fine and I got back into the lot, but the 4x4 light didn't come on.

When I left and got back onto the road I looked down and the 4x4 light was on, but I could definitely tell it was in 4 Low. I limped it back the 6 blocks to my house and started doing everything I could to get it back into 2wd. I flipped the switch and it didn't do anything. I tried it a bunch of times in neutral, I backed up and slammed on the brakes (which btw my adjusters also definitely work), I unplugged the switch, unplugged the motor, plugged them all back in. Nothing, still in 4 Low. I pulled the battery cables and let it sit for about 15 minutes then hooked them back up. When I did and tried the switch again something moved and the 4x4 light went out in the cluster, but it was still in 4 low.

I pulled down into my garage, unbolted the shift motor, put the trans in neutral and turned the nub back into 2wd with absolutely no problem whatsoever. It also turns out that this guy's "new" shift motor was a reman motor that looks like it survived a drop off of grand canyon minus the shiny "new" black paint and the "reman" stamped over that.
Also, the brown or tan wire that comes out of the t-case (which I have no idea what it does) was cut and "reattached" to the "new" motor by twisting the wire that it's supposedly supposed to go to to the cut end of the t-case wire.

What is the deal here? Am I doing something wrong with how I'm engaging or attempting to disengage the 4x4? Like is this something that's as simple as operator error? If not what is a good direction to start?

Secondly what is that tan or brown wire for and what does it hook up to should I want to get another shift motor should the one I have be toast.

Thanks!

 

[cvar]

Sounds like your shift motor just needs an internal cleaning & lube. No biggie.
Good that your transfer case is OK.

Have you seen the tech library yet? http://www.therangerstation.com/tech_library/transfercasetroubleshooting.shtml

Oh, and the shift motor needs constant exercise (eg, 1x per month) just to avoid seizing up. Some of us develop a habit of using it for 1 minute whenever it rains/snows.

BTW, 4x4 low switching has special interlocks, so vehicle must be stopped, gearshift in Park/Neutral, plus requires foot on brake, or else it won't switch IN/OUT of 4x4 LOW. OTOH, switching between 4x4 high and 2WD mode works on the fly, even while moving at speed.

 

[4.0B2]

Sounds like your shift motor just needs an internal cleaning & lube. No biggie.
Good that your transfer case is OK.

Have you seen the tech library yet? http://www.therangerstation.com/tech_library/transfercasetroubleshooting.shtml

Oh, and the shift motor needs constant exercise (eg, 1x per month) just to avoid seizing up. Some of us develop a habit of using it for 1 minute whenever it rains/snows.

BTW, 4x4 low switching has special interlocks, so vehicle must be stopped, gearshift in Park/Neutral, plus requires foot on brake, or else it won't switch IN/OUT of 4x4 LOW. OTOH, switching between 4x4 high and 2WD mode works on the fly, even while moving at speed.

Good Posting.

 

[Earl43P]

That brown wire is used to apply an electromagnetic clutch in the transfer case. It gets the gears in the transfer case up to engine speed so that you can shift on the fly from 2wd to 4Hi and back without a horrendous clunk. A proper splice would fix that, but when you replace a shift motor, you are supposed to de-pin that wire from the old one and pin it into the new motor's connector.


Sounds like you need another shift motor. They are all over the junkyards. New ones can be pricey. You can't use one from a modern Explorer. Just get one from a like year Ranger.

Welcome to The Ranger Station!

Now, go read these articles:

http://www.therangerstation.com/tec...ng_1995_&_Newer_Electric_Shift_Transfer_Cases

http://www.therangerstation.com/tec...g.shtml#Cleaning_The_Shift_Motor_1995_&_Newer

http://www.therangerstation.com/tech_library/TCaseshiftmotor.shtml ESPECIALLY THIS ONE!