My 4 wheel drive system seems to be dead... Need some advice.

[TheOnlyest]

Hey gang, I am a sports car guy, this is my first truck, and certainly my first 4x4. I am spending a fortune and ALL my free time trying to bring back to glory, a very abused and neglected 2003 XLT 4x4 4.0L 4D Supercab Flareside that I just bought 5 weeks ago. So far I have been focused on upgrades, appearance details and trying to source all the parts that were/are broken, damaged or missing from it. I am a very proficient mechanic and have just about every tool that exists. I have a few mechanical issues to work out, but one of them I am clueless about...
When I change the switch from 2wd to 4 high or low, nothing happens! The 4 high and low lights on the cluster don't come on or anything. The only thing I have done is check all the related fuses, and they are all good. I did a refurb on the center dash panel, so I know the switch is connected correctly, but the green light in the switch doesn't work either.
I also have no idea if the truck is currently in 2wd or 4wd, but I have a feeling its in 4wd by the way it drives and how gutless it is.
Could you guys please tell me what you'd be looking at if you had these symptoms?

 

[rusty ol ranger]

View attachment 122507
Hey gang, I am a sports car guy, this is my first truck, and certainly my first 4x4. I am spending a fortune and ALL my free time trying to bring back to glory, a very abused and neglected 2003 XLT 4x4 4.0L 4D Supercab Flareside that I just bought 5 weeks ago. So far I have been focused on upgrades, appearance details and trying to source all the parts that were/are broken, damaged or missing from it. I am a very proficient mechanic and have just about every tool that exists. I have a few mechanical issues to work out, but one of them I am clueless about...
When I change the switch from 2wd to 4 high or low, nothing happens! The 4 high and low lights on the cluster don't come on or anything. The only thing I have done is check all the related fuses, and they are all good. I did a refurb on the center dash panel, so I know the switch is connected correctly, but the green light in the switch doesn't work either.
I also have no idea if the truck is currently in 2wd or 4wd, but I have a feeling its in 4wd by the way it drives and how gutless it is.
Could you guys please tell me what you'd be looking at if you had these symptoms?

If the light on the knob isnt coming on i would check to see if A) there is power to the switch and B) if the switch is working.

Im not sure what plug does what on those. I also believe there is a module that controls it...someone more familiar with the newer trucks can pry help more there.

As far as it being in 4wd, find a gravel parking lot (i wouldnt do it on pavement) and turn the wheels and accelerate a bit, if you feel it bind and push its in 4wd.

If it is indeed in 4wd i wouldnt be driving it untill i either pulled the front drive shaft or took off the Tcase motor and manually flop it over to 2wd.

4wd and pavement can play hell with the transfer case in pretty short order unless all you do is drive straight

 

[SenorNoob]

The newer ones may be more forgiving, but if I backed out of that driveway with my 4wd locked in, something would break.

 

[pjtoledo]

yep, if it's in 4wd a sharp turn puts massive bind on the drivetrain, on pavement.

you can remove the transfer case shift motor. that will expose the shifting shaft which points to which mode it's in.

 

[Uncle Gump]

Transmission, Transfer Case & Driveshaft - The Ranger Station

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[CrabGuy]

I bought an 04 with the 4wd not engaging or lighting up on the dash at startup. I ended up replacing too many parts. My main problem was the 4WD module was bad. I replaced the shift motor also since it is pretty cheap as an aftermarket part. My shift module kept blowing a 10A fuse in the PS kick panel until I replaced it. A new shift module is pricey. It was about $140 at RA. I kept the old motor after it tested good. Once you get it working again be sure and exercise the 4WD monthly on gravel or dirt roads.

 

[TheOnlyest]

Thanks for all the advice and feedback guys! I did some more recon today...
I got out the ol contact cleaner and douched every related connector, and I have gained the following as a result...
-The 4wd high and low cluster lights do work, they don't come on in test when you turn the ignition on, but as soon as you start it, they both go on and off quickly. (which leads me to believe that I am in 2wd mode)
- The green light in the switch now comes on when the lights are on.
- If I change the mode switch to anything else, a relay in the 4x4cm starts clicking on and off repeatedly for about 30-40 seconds and then stops. If I change to a different mode on the switch, the relay clicking cycle starts again. Neither light on the cluster comes on when I switch to either 4wd mode. So at least it seems that the switch is fine.

Does any of that help to isolate the problem?

 

[TheOnlyest]

Perhaps I should replace this motor, just because...

 

[sgtsandman]

My first inclination is that it's the motor. Looking at the picture, it is a reasonable assumption but don't be surprised if it ends up not being the problem. I do have the luxury of owning a service manual and wiring manual. So I have something to reference during troubleshooting before I start replacing parts.

Unfortunately, I'm not home to provide scans of the relevant pages for you. Good luck.

 

[TheOnlyest]

For the record, that ugly motor I posted above, works fine. I replaced it anyway...
Replacement 4x4cm on the way, but i'm not optimistic.

 

[TheOnlyest]

ok then, I stand corrected, the new 4x4cm brought my 4WD back to life! All good now.

 

[Mechrick]

Perhaps I should replace this motor, just because...

That truck is clearly *not* from Las Vegas...

 

[rumblecloud]

ok then, I stand corrected, the new 4x4cm brought my 4WD back to life! All good now.

Great to hear and thank you for posting the outcome.
Lots of posters don't and that's

EDIT: Nice lookin' truck BTW.

 

[TheOnlyest]

That truck is clearly *not* from Las Vegas...

Correct, it was purchased new in Ohio and brought to Las Vegas in 2014. There is no rust anywhere on the body, but the bed was rusty underneath, but I have replaced it with a true Vegas bed that is incredibly clean and immaculate.

 

[TheOnlyest]

Great to hear and thank you for posting the outcome.
Lots of posters don't and that's

EDIT: Nice lookin' truck BTW.

Agreed... So in summary... If you switch drive modes and hear a relay clicking on and off continuously in your right kick panel, for about 30 seconds and then stops... Your 4x4cm is bad.