4x4 Problems

[tuna_641]

Well I have been lurking on the ranger station picking up tips here and there and I have finally have a problem for the pros!
Im trying to give my little brother an hand fixing his 1999 Ranger XLT Xcab. His 4x4 quit working and I figured that it would be an easy fix. Low and behold Im about to pull out my hair and drive it off a cliff.
Ok ,so to start the 4x4 light is doing the blink every 2 minutes. So far I have checked all fuses in the cab fusebox and the box under the hood. All seem to be good. Ive wire brushed two grounds that I found in the cab. Next I changed the transfer case motor, still nothing. I've put on a set of Rugged Ridge locking hubs. Also went to the salvage yard and got a GEM module, had it programmed at Ford. Also installed a transfer case relay module. I unhooked the battery and let it sit for an hour then gave it a try. I should note that when I tried this the first time I had the transfer case motor loose so i could see if the motor was turning. I can hear the relay in the cab click and the motor jumps but does not turn. I hooked 12 v to the motor and it works fine. So I tested the wire going to the motor and only get 9 v. Now I am once again getting the 4x4 light flashing and no clicking in the relay. Checked all fuses once again and they are still ok. His dome light stays on intermittently also so I don't know if this is still leaning toward a bad GEM module again or his door sensors are going bad. I soaked them with WD 40. Any other tips or advice for me would be greatly appreciated! Im about to throw in the towel. Also I shifted the transfer case manually into 4x4 hi with the hubs locked and it all works fine.

 

[RonD]

You probably have a Borg Warner 1354 transfer case, electric shift, 1999 should have a Brown Clutch wire on the shift motor wiring, it connects to the transfer cases "clutch", this allows you to drive in 4WD on dry pavement, 4WD module cycles clutch on and off, there were transfer case speed sensors on some models(along with VSS on rear axle), not sure about the 1999 Ranger.
If brown wire is disconnected light will flash.

Here is a diagram of the wiring: http://ww2.justanswer.com/uploads/h...1999_ford_ranger_electric_shift_control_1.pdf

 

[tuna_641]

Yes , there is a brown wire that I had to connect to the new motor when I installed it that goes into the transfer case. I will check for the two sensors.