Question about 2003 Ford F250

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2003 ford f250 superduty 4x4 don't work no indicator light on dash changed4x4 switch module what next?

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Check for codes. Usually part stores do it for free. here is how it works.
Principles of Operation

Electronic Shift on the Fly (ESOF) System

The electronic shift on the fly (ESOF) system is an electronic shift system that allows the operator to choose between 2 different 4x4 modes as well as 2-wheel drive. The operator can switch between 2H and 4H mode at speeds up to 88 km/h (55 mph). To engage or disengage 4L, the 4x4 generic electronic module (GEM) requires that the vehicle speed be less than 5 km/h (3 mph), the brake pedal depressed and the transmission in NEUTRAL (or clutch pedal applied on manual transmission vehicles). This system contains pulse vacuum hublocks (PVH). The selector on the hublock, when turned fully counterclockwise to the AUTO position, engages/disengages the hub depending on the driver-selected 4x4 mode of operation. The hublocks also contain a manual override. When the selector is rotated fully clockwise to the LOCK position, the 4x4 vacuum and electronic system used for coupling the front axle to the wheel is bypassed.

The transfer case is equipped with a dual-cone synchronous clutch. This clutch is used to synchronize the front driveline to the rear. All other internals operate in the same manner as the manual shift system. When the mode select switch (MSS) on the instrument panel is turned, the 4x4 module powers the transfer case motor, which activates a shift fork and engages the clutch. When the shift motor reaches the desired position, as determined by the encoder position inputs to the 4x4 module, power to the shift motor is removed. When the transfer case front and rear output shafts are synchronized, the lockup collar mechanically engages the mainshaft hub to the drive sprocket. At this point, the front axle PVHs are engaged. Instrument cluster "4x4" and "Low Range" indicator operation is controlled via hardwired outputs from the 4x4 module.

Electronic Shift Transfer Case

The New Venture Gear NV 273 electronic shift transfer case is a 3-piece aluminium design. The unit transfers engine power from the transmission to the front and rear axles. Under normal driving conditions the unit is in 2-wheel drive high (2H), but when desired, the operator may shift into 4-wheel drive high (4H) or 4-wheel drive low (4L). The transfer case is shifted electronically. The unit is lubricated by a positive displacement fluid pump that channels fluid flow through holes in the mainshaft.

The encoder assembly used for mode indication is of a Hall-Effect type. The system uses a total of 4 independent transistors for mode recognition. Each transistor is associated with a specific range of motor movement. When the circuit to each transistor is closed, a ground path to any of the A, B, C or D encoder pins is accomplished. When the circuit to each transistor is open, the connection to any of the A, B, C, or D encoder pins is pulled to voltage. Mode indication is "decoded" by the 4x4 module based on the varying combinations of signals coming from the transistors.

Hublock Operation

With the hublocks in the Auto position, the 4x4 ESOP system uses timed vacuum sequences to lock and unlock the wheel ends when switching the instrument panel MSS between 2WD and 4x4 modes. A high vacuum level (222 mm or 8.75 in. Hg and greater) is applied to the hublocks to lock the internal spring mechanism that engages (locks) the hublocks for 4x4 mode, and a lower vacuum level (114 to 184 mm or 5.9 to 7.1 in. Hg) is applied to unlock the spring mechanism that disengages (unlocks) the hublocks for 2WD mode. The vacuum signals are supplied to the hublocks by system components, including the 4WD control module or GEM, wiring harness, solenoid, vacuum harness and vacuum seals. As a first step in service, eliminate obvious items such as loose wiring connections, loose vacuum connections or damaged vacuum lines.

Posted on Dec 12, 2014

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