Question about 1993 Ford Explorer Limited

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Transfer case shift motor - 1993 Ford Explorer Limited

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  • warlock61
    warlock61 May 11, 2010

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I have a 1992 ford explorer 4x4, transmission will not pull at all, in any gear, could this be an actuator motor problem? I went to some other forum be no one said anything about no gears just it would not shift from 4 to 2 wheel drive,I have no gears. Thanks for any help Bert

Posted on Feb 16, 2009

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1998 chevy blazer four wheel drive not engageing


You replaced all those parts without knowing what is wrong , you like making parts stores rich ? Did you have it checked for DTC'S - diagnostic trouble codes ?
Transfer Case Control Module Description
The TCCM performs the following functions:
• Receives input signals
• Processes the signal information
• Develops output signals
• Sends the output signal in order to control the shifting of the transfer case
The TCCM receives input signals from the following sources:
• The transfer case shift select buttons
• The NSBU switch on the vehicles with automatic transmissions
• The clutch position switch on the vehicles with manual transmissions
• The vehicle sped sensor calibrator module
• The encoder/motor range and the mode feedback signals
• The diagnostic enable
• The front axle mechanical status signal
In order to ensure the electronic shift system is operating properly, the transfer case control module (TCCM) continually performs diagnostics checks on itself and other parts of the electronic shift system when the ignition switch is in the run position. The following are different types of system checks that the TCCM continually performs.

Motor and Relay Voltage Checks
Whenever the electric-shift motor is turned ON or OFF the motor and the electrical circuits are tested both in the de-energized and energized condition. If one or both voltage relays fail to detect the proper voltage after energizing or de-energized and energized condition. If one or both of the voltage relays fail to detect the proper voltage after energizing or de-energizing, the shift is aborted by the TCCM and a DTC of 3 is stored in order to indicate a faulty TCCM motor circuit.
If one or both relays fail to detect the proper voltage after de-energizing, both relays are turned ON by the TCCM, (even with the ignition switch positioned OFF) in order to prevent the motor from running. The TCCM then stores a DTC of 3 in order to indicate a faulty TCCM motor circuit. All of the status lamps blink three times, stop, and repeat the blinking continuously in order to alert the driver that the electronic shift system requires immediate repair. The battery will drain when this condition occurs, regardless of the ignition switch position.

DTC 001
DTC 002
DTC 003
DTC 004

DTC 001
The transfer case shift control module normally has battery voltage supplied to it at all times through the battery positive voltage circuit (CKT 40). When the ignition is ON, the transfer case shift control module conducts a self-test to determine if it retains the same memory it had when the ignition was last turned OFF. This self-test indicates whether the RAM standby power supply to the transfer case shift control module pin C6 was interrupted, which would result in clearing DTC's from memory. If the self-test fails the transfer case shift control module sets DTC 1.
Inspect the CTSY LP fuse for an open.

DTC 002
The transfer case encoder motor is an assembly which houses four separate channels. These channels are used to indicate to the transfer case shift control module the present gear position of the transfer case or if the transfer case is in transition between gears. The encoder motor assembly consists of an electronically conductive inner ground ring in contact with a three legged wiper arm. Each leg's length is such that it makes contact with the conductive regions of the four channels. When any leg of the wiper arm is making contact with the conductive area of any channel, the encoder provides a path to ground to the inner ground ring.
During electronic shifting, the transfer case shift control module monitors the transfer case encoder circuit for the proper operating sequence. If at any time during a shift, the encoder changes from one position to any position other than the next possible position, an error counter in the transfer case shift control module increments by four. After the counter reaches 32, the transfer case shift control module set a DTC 2, a permanent "encoder fault," and reverts to a 2HI to 4LO or a 4LO to 2HI shift pattern only. To guard against a transient, random encoder fault due to vibration, dirt, electrical noise, etc., the fault counter reduces by one each time the transfer case shift control module detects a valid encoder value. The encoder must intermittently fail 25 percent of the time for the transfer case shift control module to consider it faulty and store DTC 2.

DTC 003
Circuit Description
The transfer case encoder motor has a bi-directional, permanent magnet, D.C. motor. When energized, (through Motor Control A or Motor Control B, the ground is provided by the opposing motor control circuit and then grounded through the transfer case shift control module ground circuit), the motor, through a series of gears, rotates a shaft which moves the mode and range forks to shift the transfer case between 4H, 2HI, and 4L ranges.
This DTC detects a short or open in the battery positive voltage circuit (CKT 1640), ground circuit, an internal short in the motor windings and related circuitry, or an internal transfer case shift control module failure.
Action Taken When the DTC Sets
In the event that one of the motor control circuits is energized (battery voltage is applied) the transfer case shift control module will energize the other motor control circuit to keep the motor from running. All switch indicator lamps will flash continuously to prompt the driver that service is required. The transfer case system will be disabled and the transfer case shift control module will remain energized even with the ignition in the OFF position.
Conditions for Clearing the DTC
The condition for setting the DTC is no longer present and a momentary loss of battery power at the battery positive voltage circuit (CKT 40).
Diagnostic Aids
When the vehicle is equipped with a manual transmission the clutch pedal must be depressed and working correctly in order for the transfer case to shift to the 4 low position. In order to confirm that it is operating correctly go the engine data 1 screen under the engine data display and observe the clutch pedal switch parameter.
Test Description
The numbers below refer to the step numbers on the diagnostic table.
This step tests the battery positive voltage circuit (CKT 1640) for an open or high resistance.
This step inspects the ATC fuse for an open.
This step tests the ground circuit.
This step tests the Motor Control A and B circuits.
DTC 3 -- TCCM Motor Circuit Step
Action
Value(s)
Yes
No
1
Important: Check the transfer case shift control module for DTCs. The transfer case shift control module is not a class 2 device. DTCs are displayed on the transfer case shift control switch. Use the following four steps to obtain DTCs.
Turn OFF the ignition for 10 seconds.
Connect PIN 13 on the data link cable (DLC) to a ground. The DLC is located in the cab under the instrument panel on the driver's side.
Turn ON the ignition, with the engine OFF.
Observe the transfer case shift control switch select buttons for flashing codes.
Did you perform A Diagnostic System Check - Transfer Case?
--
Go to Step 2
Go to Diagnostic System Check
2
Turn ON the ignition, with the engine OFF.
Backprobe and measure battery positive voltage (CKT 1640) at the transfer case shift control module.
Does the voltage measure near the specified value?
B+
Go to Step 6
Go to Step 3
3
Inspect the ATC Fuse 20A.
Is the fuse blown?
--
Go to Step 5
Go to Step 4
4
Repair the battery positive voltage circuit (CKT 1640) for an open or high resistance. Refer to General Electrical Diagnosis and Wiring Repairs in Wiring Systems.
Did you complete the repair?
--
Go to Step 11
--
5
Repair the battery positive voltage circuit (CKT 1640) for a short to voltage or short to ground. Refer to General Electrical Diagnosis and Wiring Repairs in Wiring Systems.
Replace the ATC Fuse.
Did you complete the repair?
--
Go to Step 11
--
6
Connect a test lamp from the battery positive voltage circuit (CKT 1640) to the ground circuit at the transfer case shift control module.
Does the test lamp illuminate?
--
Go to Step 8
Go to Step 7
7
Repair the ground circuit for an open or high resistance. Refer to General Electrical Diagnosis and Wiring Repairs in Wiring Systems.
Did you complete the repair?
--
Go to Step 11
--
8
Backprobe and measure voltage at the transfer case shift control module between the transfer case motor control A circuit and the transfer case motor control B circuit.
Press the 4HI then 4LO on the shift control switch.
The DMM should read +12V in one direction and -12V in the other direction.
Does the voltage measure near the specified value?
+12V/-12V
Go to Step 9
Go to Step 10
9
Repair the open or high resistance in the transfer case motor control A or B circuits. Refer to General Electrical Diagnosis and Wiring Repairs in Wiring Systems. If OK, replace the transfer case encoder motor. Refer to Motor/Encoder Replacement .
Did you complete the repair?
--
Go to Step 11
--
10
Replace the transfer case shift control module. Refer to Transfer Case Shift Control Module Replacement .
Did you complete the replacement?
--
Go to Step 11
--
11
Clear all DTCs from memory. Refer to Diagnostic Trouble Code (DTC) Clearing .
Operate the vehicle while pressing each of the buttons on the transfer case shift control switch.
Does the DTC reset?
--
Go to Step 2
System OK

There is a bit more to it then just replacing parts ! Your best bet - Take it to a qualified repair shop .

Feb 07, 2017 | Chevrolet Blazer Cars & Trucks

1 Answer

I own a 02 foard explorer shift motor was bad i think and i removed it, i started it to relocate it, installed the new shift motor


Don's 1999 Ford Ranger shift motor PROBLEM SOLVED ...

? 13:05
https://www.youtube.com/watch?v=wcn39gwPWfI
Oct 1, 2013 - Uploaded by gtarman49
Don's 1999 Ford Ranger shift motor PROBLEM SOLVED. ...How to find replace fix 4x4 transfer case shift module 2002 Ford Explorer 4 wheel ...

How To Install Replace 4x4 Transfer Case Shift Motor Ford ...

? 9:15
https://www.youtube.com/watch?v=9ldrtZODxQ8
Oct 26, 2010 - Uploaded by 1A Auto Parts
How To Install Replace 4x4 Transfer Case Shift Motor Ford Explorer .... transfer case shift module 2002 Ford Explorer 4 wheel drive not working ...

How to find replace fix 4x4 transfer case shift module 2002 ...

? 3:07
https://www.youtube.com/watch?v=sZw3SS2Pt-4
Nov 3, 2013 - Uploaded by kirk colombo
... transfer case shift module 2002 Ford Explorer 4 wheel drivenot working ..... I replaced the transfer motor so i think it is the control module.


Jan 08, 2016 | Cars & Trucks

1 Answer

My 98 f150 was in 4WD Hi this morning when I started it. Selector switch is in 2WD position. 4WD Hi light is on, hubs (or front differential) is engaged and transfer case engage. (Feel front wheel hop...


If the switch was in the 2WD position and the transfer case was locked in a 4WD range, my 2 SWAGs would be bad switch or the connector to the shift motor is damaged / corroded or the fuse to the transfer case shift relay module is blown ( fuse # 17 ) / problem with the transfer case shift relay module.

This is without knowing if the truck was used in 4WD the night prior, and shifted out just before turning off. If this is the case, the shift motor might be stuck, and a few hits with a dead blow hammer to the transfer case might jar it free again ( do not use a metal hammer, it could damage the transfer case ).

The vacuum shift solenoids on the firewall are controlled by the GEM ( Generic Electronic Module ) which is grounding either the 2WD or 4WD solenoid, depending on the shift plate contacts in the transfer case. ( when in 4 or 4H, the contact switch plate signals the GEM, which in turn grounds the correct solenoid ).

Pulling the switch will not cause the transfer case to go back to a default position, the switch has a resistance level for each mode, and needs that value to operate the shift motor.

The resistance values for the switch between the 2 dark blue wires:
2WD - 4100 to 3700 ohms
4H - 1050 to 1150 ohms
4L - 380 to 340 ohms
- find the wire locations on the switch, mark them and remove the connector to test the resistance.

Just my opinion on the order :

1. Check the fuses for the shift motor
2. Try the old school shift method, back up ~ 50' put into park or neutral, and shift from 4WD to 2WD.
2.1. This is to see if the transfer case shift motor is bound up, and reversing might release it
3. Try hammering the transfer case with a dead blow hammer while someone shifts from 2WD to 4WD. You only need the key in the run position, if it happens quick enough after running the engine, the vacuum reservoir will still have enough vac to operate the solenoids. Don't chance running yourself over.
3.1. If this frees up the shift motor and the vacuum has bled off, you can try starting the truck and shifting into 4H then back to 2WD to get the front axle to disconnect or manually vacuum operate the front disconnect motor by applying vacuum to the pink vacuum line on the shift motor on the front axle.

Mar 05, 2011 | 1998 Ford F150 Regular Cab

1 Answer

Where is the transfer case shift motor located on 2004 dodge dakota


The transmission control module and the transfer case control module are separate parts. The transmission control module is mounted under the hood and controls only transmission functions. The transfer case control module controls only the transfer case, and is located inside the truck. If you remove the trim panel under the steering column you will find the transfer case control module mounted just to the right of the opening.


The shift motor is located just behind the axle tube to prevent damage.
There is a shift motor on the right front axle that is vacuum operated.
The shift motor (1) is an electromechanical device consisting of a DC permanent magnet motor, a motor brake, a gear train and an analog position sensor. The shift motors' overall function is to move and lock a gear that moves the mode fork found in the transfer case. This allows the transfer case to be shifted electrically to multiple operating positions (4LOCK and AWD). The operating current of the shift motor under
stall conditions is 30 amps maximum at 72° F with 13.5 volts, at the motor leads.
OPERATION
Shifting in the transfer case occurs when the shift motor brake is released and a Pulse Width Modulated (PWM) voltage is supplied to the shift motor by the Front Control Module (FCM). A linear analog position sensor located inside the shift motor, provides the FCM with the motors' angular, rotational position. With this information, the FCM
continuously knows the motors' position, and therefore allows it to accurately control the motors' operation, including voltage polarity which is used to control motor direction.

REMOVAL :---Note: New shift motor assemblies are shipped in the AWD position. If a new shift motor assembly must be installed, it will be necessary to shift the transfer case to the AWD position prior to motor installation.
Raise the vehicle on a suitable hoist.Remove the front propeller shaft. Disengage the wiring connectors from the shift motor and mode sensor.Remove the front output shaft companion flange from the transfer case.Remove the bolts (Remove the Shift Motor and Mode Sensor Assembly Bolts) holding the shift motor and mode sensor assembly onto the transfer case.Separate the shift motor and mode sensor assembly from the transfer case. See fig below:-- helpmech_19.gif
1 - TRANSFER CASE.2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY.3 - BOLT.-- This should help.Thanks.Helpmech.

Feb 26, 2011 | 2004 Dodge Dakota

1 Answer

KinlogworksI have A 2003 F-150 Super Crew. I have only used th4 wheel drive a few dozen times. about a mounth ago i switched it into 4 high and nothing happened. problem also in 4 low. any advise?


Operationally vacuum shifts the front axle between 2WD and 4WD mode. The GEM ( Generic Electronics Module ) applies ground to the solenoid needed for the mode selected on the switch ( for ESOF ) or when the transfer case shift lever is moved ( MSOF ). The contact plates in the transfer case signal the GEM that the transfer case is engaged, and the Vacuum solenoids need to be activated ( either 2WD to 4WD or 4WD to 2WD ).

Lift and support the front of the truck so the front wheels are off the ground ( take safety precautions, chock wheels, jack stands, etc )
Key on, engage 4x4 and try to turn the front drive shaft.
- If it turns it is a problem with the transfer case.
- If it doesn't it is a front axle engagement problem.

- If the front drive shaft does not turn :
•With the truck running ( with front wheel back on the ground ), switch from 2WD to 4WD and back again, the vacuum shift motor should move the lever on the front axle.
{ picture of shift motor }
-- If the vacuum shift motor does not move:
•Check for vacuum on the lines while shifting between modes. Pink vacuum line is 2WD mode, Light Blue vacuum line is 4WD.
•Check the fuses for the 4WD system and the solenoids.
•Check the vacuum lines from the vacuum shift motor to the solenoids on the firewall.
•Check the vacuum lines from the solenoids to the vacuum reservoir box behind the battery.
•Check the vacuum reservoir box for cracks.
•Typical solution is the vacuum lines ( to the solenoids or to the vacuum shift motor ) are cracked or the vacuum shift motor has a cracked diaphragm and has water in it.
•Could be the shift plate contacts in the transfer case are corroded / not making good contact, and not activating the solenoids.
{ Picture of Vacuum diagram )

- If the front drive shaft turns:
•For ESOF system
-- Check the fuses for the transfer case, engine compartment fuse panel, 17 & Cab fuse panel fuses 13 and 23 ( verify with owners manual, 97-97 & 99-03 MY can be slightly different on some items ).
-- Try hitting the transfer case with a dead blow hammer ( do not use a metal hammer, it can damage the transfer case ) to see if the transfer case shift motor is hung up .
-- Check the transfer case connector, to make sure the connector pins are clean and making good contact.
•For MSOF systems
-- Check that the shift linkage on the transfer case is moving when the lever is moved from 2W to 4H and 4L.

Jan 18, 2011 | 2003 Ford F150 Regular Cab

1 Answer

2003 F-150 regular cab automatic transmission and the 4WD will not engage.


Operationally vacuum shifts the front axle between 2WD and 4WD mode. The GEM ( Generic Electronics Module ) applies ground to the solenoid needed for the mode selected on the switch ( for ESOF ) or when the transfer case shift lever is moved ( MSOF ).The contact plates in the transfer case signal the GEM that the transfer case is engaged, and the Vacuum solenoids need to be activated ( either 2WD to 4WD or 4WD to 2WD ).


Lift and support the front of the truck so the front wheels are off the ground ( take safety precautions, chock wheels, jack stands, etc )
Key on, engage 4x4 and try to turn the front drive shaft.
- If it turns it is a problem with the transfer case.
- If it doesn't it is a front axle engagement problem.

- If the front drive shaft does not turn :
•With the truck running ( with front wheel back on the ground ), switch from 2WD to 4WD and back again, the vacuum shift motor should move the lever on the front axle.
{ picture of shift motor }
-- If the vacuum shift motor does not move:
•Check for vacuum on the lines while shifting between modes. Pink vacuum line is 2WD mode, Light Blue vacuum line is 4WD.
•Check the fuses for the 4WD system and the solenoids.
•Check the vacuum lines from the vacuum shift motor to the solenoids on the firewall.
•Check the vacuum lines from the solenoids to the vacuum reservoir box behind the battery.
•Check the vacuum reservoir box for cracks.
•Typical solution is the vacuum lines ( to the solenoids or to the vacuum shift motor ) are cracked or the vacuum shift motor has a cracked diaphragm and has water in it.
•Could be the shift plate contacts in the transfer case are corroded / not making good contact, and not activating the solenoids.
sscullys_111.jpg

- If the front drive shaft turns:
•For ESOF system
-- Check the fuses for the transfer case, engine compartment fuse panel, 17 & Cab fuse panel fuses 13 and 23 ( verify with owners manual, 97-97 & 99-03 MY can be slightly different on some items ).
-- Try hitting the transfer case with a dead blow hammer ( do not use a metal hammer, it can damage the transfer case ) to see if the transfer case shift motor is hung up .
-- Check the transfer case connector, to make sure the connector pins are clean and making good contact.
•For MSOF systems
-- Check that the shift linkage on the transfer case is moving when the lever is moved from 2W to 4H and 4L.

Jan 10, 2011 | 2003 Ford F150 Regular Cab

1 Answer

Transfer case grinds truck only runs in 4wheel low nothing in 4wheel high or 2wheel drive


Manual or electronic t case?

Section 07-07: Transfer Case, 4x4 System, Service 1994 Bronco/Econoline/F-Series Workshop Manual
DESCRIPTION AND OPERATION Electronic Shift Operation The transfer case is equipped with a magnetic clutch, similar to an air conditioning compressor clutch, which is located inside the transfer case adjacent to the lockup collar. The clutch is used to spin up the front drive system from zero to vehicle speed in milliseconds. This spin-up allows the shift between 2-high and 4-high to be made at vehicle speeds listed in the vehicle owner's guide. The spin up engages the front lock hubs. When the transfer case rear and front output shafts reach synchronous speed, the spring-loaded lockup collar mechanically engages the mainshaft hub to the chain drive sprocket and the magnetic clutch is then deactivated. Shifts between 4-high and 4-low can only occur with the transmission safety switches closed. The vehicle's speed must also be within specified limits as determined by the transfer case speed sensor (3 mph or under). Electronic Shift Control System
This system consists of a two-switch control system, an electronic control module, an electric shift motor (7G360) with an integral shift position sensor, and a speed sensor. Switch Control System
There are two control switches located on the upper right corner of the instrument panel for fingertip shift control. The two switches are mounted horizontally and are identified as "4x4" and "LOW RANGE". Two indicator bar lamps are located in the instrument cluster.

c11148a.gif

When either of the two switches on the instrument panel control are depressed, the first thing that happens is that the electronic control module receives input from the transfer case shift position sensor to verify what position the transfer case is in (2H, 4H or 4L). Next, the electronic control module looks at the speed sensor and the park/neutral position switch or clutch pedal position switch (depending on transmission type). If all conditions are correct to allow the desired shift, the electronic control module will tell the electric shift motor to execute the shift. After the shift has been made and the electric shift motor is off, the control module again looks at the shift position sensor to make sure the proper shift has been accomplished. Finally, the dash indicator light and the pushbutton light on the control panel will be illuminated by a signal from the electronic control module indicating the desired function has been completed.
Electronic Control Module
The electronic control module, located on the passenger side, controls the operation of the transfer case in response to inputs to the pushbutton control by the vehicle operator, the speed sensor, shift position sensor and the park/neutral position switch. Speed Sensor
The speed sensor, mounted on the rear of the transfer case , tells the electronic control module the speed of the vehicle to allow range shifts (in or out of 4L) to occur. Shift Position Sensor
The shift position sensor, an integral part of the electric shift motor , tells the electronic control module the shift position of the transfer case . Electric Shift Motor
The electric shift motor , mounted externally at the rear of the transfer case , drives a rotary helical cam which moves the 2W-4W shift fork and 4H-4L reduction shift fork to the selected vehicle drive position.

Nov 12, 2010 | 1994 Ford F250 Supercab

2 Answers

4wd does not work


Electronic Shift On the Fly (ESOF) Operation
The ESOF system is an electronic shift 4x4 system that allows the operator to choose between two different 4x4 modes as well as 2-wheel drive. The operator can switch between 2WD and 4WD HIGH mode at speed. To engage or disengage LOW Range, the vehicle speed must be less than 5 kph, the brake depressed, and the transmission must be in NEUTRAL.

The transfer case is equipped with an electromagnetic clutch which is located inside the case. This clutch is used to spin up the front drive-line when shifting from 2WD to 4x4 High mode at speed. When the control switch on the instrument panel is turned, the generic electronic module (GEM) recognizes that a shift has been requested and activates the electromagnetic clutch and the relays which power the transfer case shift motor. When the shift motor reaches the desired position as determined by the contact plate position inputs to the GEM, power to the shift relays and motors will be removed. When the transfer case front and rear output shafts are synchronized, the spring loaded lockup collar mechanically engages the main-shaft hub to the drive sprocket. Finally, the front axle collar is engaged and the electromagnetic clutch is deactivated.

Shift Between 2WD and 4x4 HIGH:
Shifts between 2WD and 4x4 HIGH can be made at speed. Listed below are the inputs and outputs needed by the GEM to execute a change between any of these modes.

Feature Inputs:
*4WD Mode Switch (Various resistances).
*Contact Plate Position Inputs A, B, C, D (grounded when closed, open circuit when open).

Feature Outputs:
*4x4 Shift Motor Relay Outputs
*Transfer Case Clutch Relay (grounded when relay is on, open circuit when relay is off).
*4x2/4x4 Vacuum Solenoid (grounded when activated, open circuit when deactivated).
*Cluster Indicators (ground when activated, open circuit when deactivated).

Shifting Into/Out of 4WD LOW:
When shifting into or out of 4WD LOW, the GEM requires that the vehicle speed be less than 5 kph, the brake is applied, and the transmission is in NEUTRAL.

Feature Inputs:
*4WD Mode Switch (Various resistances).
*Contact Plate Position Inputs A, B, C, D (grounded when closed, open circuit when open).
*VSS Sensor (Sinusoid Signal: 0.7V-20V, 2.2 Hz/mph).
Brake Input (battery voltage when brake is depress, open circuit when not activated).
*Transmission Range Sensor (grounded when transmission is in NEUTRAL, open circuit otherwise).
8Start/Clutch Depressed Input

Feature Outputs:
*4x4 Shift Motor Relay Outputs
*4x2/4x4 Vacuum Solenoid (grounded when activated, open circuit when deactivated).
*Cluster Indicators (grounded when activated, open circuit when deactivated).

4WD Mode Switch
A rotary switch allows the vehicle operator to choose between 2WD, 4WD HIGH, and 4WD LOW modes of 4x4 operation.

GEM Module
The Generic Electronic Module (GEM) controls the operation of the 4x4 system

Vehicle Speed Sensor
The vehicle speed sensor (VSS), mounted in the rear of the transfer case, informs the GEM of the vehicle speed.

Transfer Case Shift Motor Sense Plates

The shift motor sense plate, an integral part of the electric shift motor, informs the GEM to the positions of the transfer case

Transmission Range Sensor
Located on the left side of the transmission, this sensor informs the GEM when the transmission is in the NEUTRAL position.

Electric Shift Motor
The electric shift motor, mounted externally at the rear of the transfer case, drives a rotary cam which moves the mode fork and range fork within the transfer case to select between the 2WD, 4WD HIGH, and 4WD LOW positions.

4x4/4x2 Vacuum Solenoids
These two solenoids are attached to the upper RH side of the engine compartment dash, and alternately route vacuum to the vacuum motor which engages/disengages the center axle disconnect collar in the front axle assembly.

4x4 Shift Motor Relay
A module containing two relays which under the control of the GEM, shift the transfer case shift motor between the 2WD, 4WD HIGH, and 4WD LOW modes.

Transfer Case Clutch Relay
An electromechanical relay is used to activate the transfer case clutch within the transfer case.

Good luck and hope this helps,but start with the simple and check the fuses and wire harness. Both white/light blue stripe wires should have 12V in run. The GEM will ground the left side (closest to engine) solenoid to disengage the front axle. It will ground the the right side solenoid (closest to fender) to engage the front axle. If the GEM doesn't see Neutral it will not let the truck come out of 4Lo. If the GEM had water leaking on it it may well be the root of the problem. The shift motor only has power when the GEM sends it a signal to move the shift lever. Once the shift is completed the motor shuts off. There are 2 wires that control the shift motor. A yellow and an orange. The GEM alternates between 12v and Ground to these wires to control which way the motor turns. The GEM uses the transfer case shift relay module to control the power to the motor. There are contact plates inside the shift motor assembly that indicate the position that the shift lever is in. This is what the GEM used to know what the T-case is doing. Any one of these components can fail.







Jan 10, 2010 | 2002 Ford Explorer

1 Answer

1996 ford explorer 4wheel drive will not engage into the hubs need to know how it works


make sure your 4WD switch is working.and fuse is okay.because your 4WD is control by 4 electric shift motors in which drive a rotary cam which moves the mode fork and range fork inside the transfer case to select between 2WD HIGH A4WD - 4WD HIGH AND 4WD LOW RANGE.a shift motor sensing plate on the shift motor monitors the range in which the transfer case is operating a transmission range sensor monitors the gear position of the transmission.which must be in neutral to shift into low.a pair of solenoids one for 2WD one for 4WD.mounted on the upper right firewall route vacuum to the vacuum motor which engages and disengages the center axle disconnect collar in the front axle assembly.a 4 x 4 shift motor relay module contains two GEM controlled relays which shift the transfer case shift motor between 2WD and 4WD modes.a solid state clutch relay activates the A4WDclutch inside the transfer case.

Dec 13, 2009 | 1996 Ford Explorer

2 Answers

Transfer case wont engage


shift into 4wd and move truck a couple of feet.
if light is still off, park truck block the wheels set the park brake jack right front wheel and try to hand spin the wheel if wheel doesn't turn 4x4 is functioning properly but there is a wiring problem use an ohmmeter to check the 4x4 switch wiring fuse and bulb
if wheel turns freely the front axle or transfer case is not engaged
attempt to hand spin the front driveshft if the driveshaft will spin the transfer case is not engaged check the transfer case shift linkage, problem is in linkage or transfer case internals
if the driveshaft will not spin the transfer case is engaged properly
with trnsmission in neutral or park start engine measure vacuum on the two vac lines at front axle shift motor . one line should have approx 20" vacuum. other line should have none
if no vacuum measured look for vac leak or bad vac switch
if both lines have vac look for a bad vac swithc or ruptured cad actuator diaphragm
if one line has 20" +- VAC
move transfer case lever to 2wd measure vac again lines should have swapped vac signals
if no vac switch bad or 4wd shift likage needs adjusting
if yes vac motor bad or stuck or shift fork stuck
remove vac shift motor from the axle attach vac lines to shift motor engage disengage 4wd
does shift motor plunger move at least 1/2 inch
no shift motor bad
yes check axle shift fork and vac motor for binging

Jan 27, 2009 | 1999 Dodge Ram

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