Newbie 1997 Ranger 4x4 Transfer case issues

[martini]

Hey everyone,

Awesome forums, I sure am glad I found them. I just got my hands on a 1997 Ranger XL 4x4 Stepside and am having trouble with 4x4. I've done exhaustive reading on here and other sites as I am new to trucks and 4x4's especially. As near as I can tell Im running the BW1354 electric transfer case and it keeps getting stuck in 4Hi. It happened the first night i got the truck but then when i was changing the tires that week i gave the front driveshaft a spin and it locked up and the next time i drove it it was fine, but then it happened last night again and I cant seem to get it out now. I suspect from my reading that the problem lies in the electric shift motor which I am looking for a replacement for but there is one wire that runs from the connector up to what i think is the transfer case; I think it might be a ground; my question is, how do i get it unhooked? I pulled on it pretty hard with pliers but to no avail.
Also, the motor is seemingly stuck in the 4hi position and I tried using a pair of pliers to turn it to 2hi (so that it would match as i had already manually switched to 2hi on the transfer case as well) but it just wont go. Am i missing something? Id really rather not be stuck in 4WD until I can get my hands on another motor from a salvage.
I also got a set of Warn manual hubs from the scrapyard but havent found a canadian supplier for the conversion kit, any canucks out there able to point me in the right direction?
Again awesome resource and great site guys, keep up the killer work.

 

[4x4junkie]

Welcome to the board!

That wire on the t-case is supposed to release from the connector, though I've never been able to figure out how to release the pin myself, so I've always just cut the wire and resoldered it (it energizes the electromagnetic clutch that spins up the front driveshaft for shift-on-the-fly operation).

The shift motor can't be turned by external means, it uses a worm gear to drive the cam gear (only way to move it is to briefly apply voltage directly to the main motor wires, or disassemble the housing and removing the gear to turn it).


Have you checked through the FAQ at the top here? There are some steps for diagnosing these systems, as well as a source for conversion nuts for your manual hubs.

 

[martini]

4x4Junkie: thanks for getting back to me. I figured I was going to have to cut that wire, so thats what i'll do. As for the shift motor, I am considering just going with one of the Shiftster contraptions as Im not particularly fond of the idea of changing that electric motor multiple times and I dont have an issue with reaching under to throw it in 4x4. Which leads me to my next question; for now, can i just remove the electric motor and manually switch using a pair of pliers until i can get some other solution or would this be dangerous to leave motor off?
Yeah Ive gone throught both faqs multiple times and Im fairly certain its the motor. As for the hub issue, I did find a thread that listed Napas part number for the conversion nuts but they dont have any in my part of the country, and im in the sticks.
Thanks again man!

 

[4x4junkie]

No, you won't hurt anything by leaving the motor off and switching it with pliers, though the t-case lacks an internal detent for the 4WD-Hi position (you'll probably only be able to use 2WD or 4WD-Lo that way). The Shiftster however does provide a detent to hold it in 4-Hi.

You don't have any Spicer distributors that could order a couple pt# 28068X's? How about a Ford dealer? or a junkyard? (nuts from an internal-hub style D44 will work on the D35 as well, such as from '73-'96 F-150s)

 

[martini]

4x4junkie: Cool, I'm going to pull the motor this afternoon then and wait for the shiftster to show up (Rick said it was going out in the mail today). It seems to be a very ingenious solution to a really common problem so hopefully it will work out as such.
As for a dana-spicer supplier, Im assuming one of the car parts places around (Napa, Carquest, Canadian Tire) would be able to order stuff from them right? There is a ford dealer but IIRC someone on one of the threads discussing alternatives to the "conversion kits" mentioned they got them from a dealer and paid $26/side. And there is a salvage yard, I just wasnt sure what I needed to ask for off of what Im still not entirely sure I do hehe... The hub locking nuts from a '73-96 f150 hubstyle d44?
Thanks again for all of your help man!

 

[martini]

Oh and I'm cleaning up the rig today so I'll post some pics tonight!

 

[4x4junkie]

Locknuts from pretty much any internal-hub style D44 (this includes the above F-150 & Bronco, '78-'91 F-250s w/ D44, '72-'91 Chevy/GMC ½ & ¾-ton trucks (to include the GM 10-bolt front axle), and 'Dodge ½ & ¾-ton trucks up thru '93. Jeep J-10 & Wagoneers also.

 

[feellnfroggy]

Sounds like you have a pretty interesting problem. BUt I didnt read where you took the motor apart and actually cleaned it (maybe I read to fast) this fixes alot of intermittent problems with the electronic t-case.

By the way, no need to label your responses, we are pretty good at deciphering them, otherwise you can use the quote option. Just trying to help save your fingertips. LOL

 

[martini]

Froggy: I havent actually busted apart the motor as yet to try and fix it; i figured after reading the tech on it it might be a bit out of my range, but now that Ive got a shiftster on the way I think i will try pulling it apart to fix it (can't make it worse right?)
Thanks guys!

 

[Guilius]

Good luck with the cleaning. It really isn't that hard and the instructions in the tech section are top notch.
And if you do happen to get in over your head, send ne a private message. I have a motor already cleaned sitting on my floor. It was leftover from when I had my issues and swapped to a manual shift case.

 

[feellnfroggy]

I was kinda worried too about doing the motor my first time, but it was alot simpler than what the article says. You cant really see common sense at work in a tech article, but it kicks in when you start pulling screws. You shouldnt have a problem. Make sure and post us an update.

 

[martini]

So ive been messing with the electric shift motor for a couple days now and cant for the life of my get any of the screws out (i broke one on the motor hosing, but the others wont move). Ive tried everything starting with wd40, percussion, heat, pb blaster plus heat, plus percussion and just cant get any of them to move; anyone have any suggestions? As I said, ive got a shiftster on the way, but id really like to pull this motor apart and see if i can fix it.
incidentally and off topic ive run into a couple of other problems now including a slight oilleak and what seems to be a vaccuum issue (p1443) but im going to try running new vaccuum lines and see if that makes a difference.
Thanks again everyone!

 

[redneck_rainey]

i have a 01 4x4 4l with the same problem, ive had to take the truck out of 4hi into 4lo and then reverse a bit, then shift to 2wd and play with reverse and drive for a bit. not fun. are the instructions for cleaning that motor gonna be the same for my truck as well? sorry for the newbie ?s

 

[MountainMike]

Ford dealer can get them, just ask for manual hub spindle nuts for your truck. A little more than the spicer ones but simple to come by. I know this 100% because I got mine from work