94 ranger 4x4

[cooldude48818]

Just bought a 94 ranger and they guy said 4x4 use to work but doesn't now. When I first test drive the truck the 4x4 and low range lights on the switch and dash were lit. The buttons did nothing when I pushed them. I bought the truck and read on how to test module and found a broken ground wire on the 4x4 computer/controller. Now I can press the 4x4 and hear the t case motor turn but no lights light up and the 4x4 doesn't work. If I push in the clutch (manual trans) and press the low range the t case motor turns and locks into 4x4 low and the 4x4 works! But then if I take it out of low range the 4x4 quits working. I have manual lock hubs. Just kinda need to know where to go next. Any Help is much appreciated

 

[RonD]

Picture here of the transfer case shifter without motor: http://www.explorerforum.com/photopost/data/500/27133Tcase02.JPG

Shift rod is pointed at 2WD

Just to test transfer case pull off the motor and manually shift to 4hi test if working then do the same for 4lo
You may need to cut the brown wire to completely remove shift motor for test drive, so have a splice connector to reinstall

Also, while motor is off, test that shift motor is moving to correct positions when 2WD, 4hi and 4lo are selected with the switch
There is a contact wheel inside the motor that tells the 4WD control module "what position" the motor is in, that wheel and contacts can get dirty inside

Pictures here of that wheel and its contacts: http://www.explorerforum.com/forums/index.php?threads/how-to-rebuild-4x4-shift-motor.123542/

The 4WD lights are on or off via the contacts on that wheel


Since you have manual hubs you can get a Shiftster to replace electric shift motor.
This allows you to manually shift transfer case, but you do need to get under the truck to do that
With manual hubs you can leave the transfer case in 4high all the time, or just in winter.
And then lock the hubs when 4WD is needed and unlock when it is not

2001 and up 4WD Rangers have locked front wheels so front axles and drive shaft are always turning, does no harm, in fact I think it is better since differential, bearings, seals, u-joints stay moving and so lubed
On the older systems you had dry starts on all those parts unless you used the 4WD often

 

[cooldude48818]

The t case motor is turning the nub on t case to far. I was able to lock it into 4x4 and then lock the front hubs in and had 4x4 up until about 35 when an awful noise and vibration shook the entire truck. I believe the front diff is junk. There was no fluid in it. Anybody have a step by step on how to remove it and put new bearings and seals in it??

 

[RonD]

Good page to bookmark here: http://www.therangerstation.com/tech_library/index.shtml

Or you can get there by clicking on the "Tech Articles" link in the tool bar at the top of this page

Then have a look at the "Axles, Gears, Hubs & Lockers" section

1994 Ranger will have a Dana front axle but you never mentioned engine size, so could be hybrid or Dana 35

Click on "Dana 28 / 35 TTB (And Hybrid) (1983-1997)" article to see what you have

Yes, dry differential can be a problem