Electric 4x4 troubles

[fordwheelinman]

Well i finally got around to seeing if i had four wheel drive today since the Ex is up on jackstands for the brakes. I have already taken the shift motor apart and cleaned it out like in the tech library, and everything went back together the way it should. When i push the 4x4 button, i have nothing lighting up. I also have no 4wheel or 4 low bulb illumination during the bulb check. Is this a problem with the 4x4 computer or something else? Electrical diagnosis isnt really my thing so if anyone can give me some advice, id appreciate it.

 

[Jspafford]

If you don't have illumination of either lights when the truck is started, I would definatly check your fuses. Assuming you have not already done so.

The computer has a button and light on it to do self diagnostics. There is a right up on it in the tech library.

 

[fordwheelinman]

i feel kinda stupid.........damn fuses..... i always forget the fuses

i just looked all over the tech library and couldnt seem to find anything about it. Where might it be?

 

[fordwheelinman]

so i looked again in the tech library, and couldnt find any write up on the 4x4 module. I remember reading about it and seeing it somewhere, but now i cant find it. Could someone please help my blindness.

 

[fordwheelinman]

Anybody?

 

[Ranger44]

There should be a way to check your 4x4 controller. There is a white button to push. Do it with the ignition on but the vehicle not running. If everything is good with it, it'll blink. Other than that there is some 4x4 relay: http://www.therangerstation.com/forums/showthread.php?t=98
on later models....I only know where things are located on Rangers not explorers, but i only asume the test will be the same for an explorer too.

When it came to mine, it would shift into 4 high no problem. Would not shift into 4low. Light would not come on. And all I heard was 2 clicks when I pushed the button. Cleaned it, like the link below and worked like a charm.

http://www.explorerforum.com/forums/showthread.php?p=1102904

Or these instructions:

I don`t have too many pics, but they`re not really needed... Here`s what I did....First, I tried all the fix ideas on the site including the shift motor rebuild and it still did not work.(still got the repeated clicking noise followed by the flashing lights) so I felt I had nothing to lose by tearing open the blue cap. I used a small flathead screwdriver to break away the tapered plastic seal.( not too much, just enough to seperate the two halves) Once seperated, pull the contact disk out and you will find the worn spots where it has been in the 2 hi position for most of the trucks life.

Take a dremmel tool or a file and smooth out the havoc you caused with your screwdiver on the housing.Clean all the contact points with alcohol and Q-tips. Use light pressure with your small flathead screwdriver and bend all four drag fingers back into the position where they will make firm contact with the position sensor disk, but use care not to over do it. If you do, the fingers will dig into the disk, killing the fingers and making deeper grooves that caused the problem in the first place. Use good quality dielectric grease and lubricate the disk and fingers. Put the wheel back into the cup trying to keep it in the 2 hi position,( not too important though, since your shift motor took a dump in 2 hi the blue cap can only be put back on the same way), put a light coat of grease on the rubber o-rings that seal the cap and put the top back on. I used a few drops of super glue to hold it in place during the re install. Put it all back together and throw it back in to your truck. Hopefully this will fix your problem. My T-case has worked flawlessly for quite some time after doing this and I`m baffled why no one else has tried it yet. Good luck and let me know how it works.


See if there is anything different with these instructions....Good Luck

 

[fordwheelinman]

Well i finally broke down and stayed late at work. Out of some stroke of luck we still have the 92 explorer manuals, so i looked it up. Found the module, found tests to perform. When i pulled the 8 pin connector out of the module to do the self test, it came out in pieces, so i think maybe thats had something to do with it, also maybe my switch. ill get into it more and read more of it tomorrow on my lunch. ill let you all know what i find.

 

[Ranger44]

That broken connector might have something to do with it. Not sure if it'll be the switch. My light didn't work either and now does(after cleaning the shift motor)....If 4 high works, it just seems to me that it would be the motor. Unless some of the wires weren't making contact in the broken connector. It's all just a process of elimintation....

 

[Jspafford]

Wait, even if the 4x4 shift motor is shot you would still have the four lights light up when the truck is started. They light to let you know the bulbs are working. So you either have something else wrong AND four bulbs burnt out, or it is something electrical.

I know you would at least have the two indicators next to the steering wheel light up, but if I remember correctly the two small lights next to the buttons themselves light up also.

 

[fordwheelinman]

im thinking my switch is bad, and the connector that was broken inside the plug on the module was making for a poor connection. Now i have yet to ohm out any wires or do any sort of true electrical testing, but that will come tomorrow.

 

[Ranger44]

I'd say test the switch or take it apart and see if anything is broken before getting a new one. The electric system is very sensitive. If it doesn't know where it is or there is one little wire with a bad connection, it won't shift. I still think it's the broken connector or the plate and brushes in the motor. Also down by the transfer case where the connector connects look inside both sides of that connector and make sure all the crude is out of there and that none of the male connectors are pushed back in the connector. How did the 4x4 controller test?

 

[fordwheelinman]

so working for a Ford dealer definately has its advantages. Ive got a new connector on its way, access to a lift so i dont have to crawl around to check my shift motor, and the factory pin point tests. HERES THE SCOOP:

I tested my wires and such according to the 92 ford book, and my bulbs check out ok, my switch checks out ok, only one of the checks so far has given a bad reading; the one for the circuit running through the motor. So if i ever get around to it, im gonna raise it up and check the circuit directly at the motor, if the resistance is out of spec, im gonna get a new motor, i already tried cleaning it when it didnt work the first time. I know ive got a thread going about swapping it out, but thats time i dont have right now. So ill see what i can come up with. Maybe ill just do like i tell my friends: SMACK DA B!TC#.

ill update on my results as i get them.

 

[Ranger44]

Cool... good luck... do let us know what you find.