Loud Bang, 4wd now dead


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PaulZ

10+ Year Member

Joined
Jul 21, 2014
Messages
167
Points
1,601
Vehicle Year
1990
Transmission
Automatic
This week I was cruising along down a paved road about 35 mph in 2wd when out of nowhere came a loud jerk and clunk, like maybe ran over a parking curb, but nothing bur smoth road. Continued on just fine. But today I tried the 4wd dash knob, which I do use often, and the 4wd hi and lo light just blink, no 4wd. I’m suspecting something broke inside. Whats next?

99 Ranger, 5 speed, manual locking front hubs I leave locked.
 
Well... When you run over a loud jerk sometimes things go clunk. :icon_twisted::icon_rofl:

When was the last time you used 4wd, was it fairly recent? Wondering if it is possible that the flashing lights and no 4wd are a separate issue from the "loud jerk and clunk".

No problems with 2wd? That means it's probably between the transfer case and the front axle.

Possible, but I doubt it is the transfer case itself, because I suspect that would show symptoms in 2wd. Given the flashing lights I would think that something electical/electronic was affected, not much in the front axle that would cause that I think. Only time I had lights flash in my '99 4wd was because of the shift motor, the 4wd system didn't give a care about the PHV system being failed.

Jerk and clunk would make me think a broken shaft, either axle or drive, but since you have the hubs locked in that should show symptoms even in 2wd and I'm not sure it would cause lights to flash. After installing the V8 AWD drivetrain the front driveshaft CV joint gave out on my truck and it definitely let you know, that's really not much different that what you would have in a live axle (or manually locked hub) 4wd truck with the axles and driveshaft turning full time.

Probably the first thing to do is get under there and look for anything broken or missing. Did the shift motor possibly leave the chat? That could definitely explain the loud clunk and flashing lights. Not a common issue, but not impossible either.

Mostly spitballing here, trying to think of things for you to look at and check on. Really not much diagnosing I can do from this side of a computer screen.
 
Just crawled under. Shift motor still there lol. I popped off the lockers, spinning the front drive shaft turns the axles so ring pinion ok i guess. No fluid leaking anywhere. 4wd lights flash maybe 10 times then quit unless I cycle the ignition key. Tomorrow ill pull that round cover on the transfer case. I last used 4wl about a week ago to get to my cabin, days and miles before this happened. Thanks for the thoughts.
 
The flashing indicator does not necessarily mean there is an electrical problem. It does mean there is a malfunction. You don't have to guess. There are several articles in the tech library for troubleshooting your 4x4 system. I recommend starting with this one.

 
If the 4wd was disengaged as it should have been on the highway there is nothing for it to break.

If you remove the t-case shift motor you can manually shift the tcase with pliers. Neutral isn't marked but it is there. Manually put it into neutral and then with the hubs unlocked see how the front driveline turns. If it turns nice then your problem is elsewhere, if it is extra chunky remove the front driveshaft and isolate it between the t-case/front diff.
 
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Thanks again. So far today I put the OBD reader on, no codes. Started it up this morning, the lights only flashed twice then went off, where ever the switch was turned. Turned engine off and back on, same. Unplugged and replugged the connector at t case, no change.
 
The shift motors had a lot of issues too, they can be cleaned/rebuilt or they are not too bad to just replace either.
 
supposed to ohm out the 4 wires at the t case connector?
 
Thanks again. So far today I put the OBD reader on, no codes. Started it up this morning, the lights only flashed twice then went off, where ever the switch was turned. Turned engine off and back on, same. Unplugged and replugged the connector at t case, no change.
Transfer case codes do not show up on OBD II. Read the articles for obtaining their codes.
 
Thanks hound, I have and tried to understand the article you posted (im 70 and missing a few brain cells). Sounds like I need a scan tool I dont have, maybe I can locate tomorrow. I did check fuse 27 and 3 under the hood, both good.
 
Check this out:


More here if it helps:

@Jim Oaks FYI, some of the links on the transfer case troubleshooting page lead to word press site logins.
 
Hey, it worked for 2 minutes!. I pulled the radio bezel, as it said somme ECM stuff back there. Don't know what im looking at but nothing unplugged. Wiggled a few connectors. Started it up and 2wl low light on solid. Drove around the block with front hubs unlocked, it was in low all right. Came back, turned to 2wd, truck went back in high but lights either out or blinking again. Wont go back in 4wl but at least nothing seems mechanically broken.
 

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