Question about 1997 Ford F250 SuperCab

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2002 f250 transfer case that doesnt shift into 4x4

2002 f250 diesel powerstroke. Has a turn dial 4x4 switch on the dash. The light in the back of the switch does have power and the 4x4 hubs work. But when I turn the switch on the dash I get no noises and more importantly no 4 wheel drive. It worked yesterday but not today. I was wondering if there is a common wire or connection that goes out in that switch? of if that motor that shifts it is going out.

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  • Da Builder May 11, 2010

    Some models had a solenoid on axle that sticks often. Worth a check.

  • Anonymous Mar 22, 2014

    gauges/horn/4x4 switch not working

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Hello , chances are the 4x4 transfer motor/solenoid on the case either has no power , or has failed. I removed mine from my 2004 Explorer , dis-assembled and replaced the nylor washer and re-assembled and she works.

Posted on Jul 25, 2009

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Posted on Jan 02, 2017

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4x4 low light on car will not move


The electronic module (located behind the glove compartment) controls the operation of the transfer case in response to inputs from the electric shift motor, 4x4 mode switch, CPP switch, BPP switch, DTR sensor, throttle position output from the PCM, front and rear OSS sensors, and the VSS. Do you know what DTC'S Are ? Diagnostic trouble codes !

P1804 4WD High Indicator Circuit Failure GEM GO to Pinpoint Test C . P1806 4WD High Indicator Short to Battery GEM GO to Pinpoint Test C . P1808 4WD Low Indicator Circuit Failure GEM GO to Pinpoint Test C . P1810 4WD Low Indicator Short Circuit to Battery GEM GO to Pinpoint Test C . P1812 4WD Mode Select Circuit Failure GEM GO to Symptom Chart. P1815 4WD Mode Select Short Circuit to Ground GEM GO to Symptom Chart. P1820 Transfer Case CW Shift Relay Coil Circuit Open or Short to Ground GEM GO to Pinpoint Test B . P1822 Transfer Case CW Shift Relay Coil Short to Battery GEM GO to Pinpoint Test B . P1824 4WD Electric Clutch Relay Circuit Failure GEM GO to Pinpoint Test A . P1826 4WD Electric Clutch Relay Short to Battery GEM GO to Pinpoint Test A . P1828 Transfer Case CCW Shift Relay Circuit Failure GEM GO to Pinpoint Test B . P1830 Transfer Case CCW Shift Relay Coil Short to Battery GEM GO to Pinpoint Test B . P1836 Transfer Case Front Shaft Speed Sensor Circuit Failure GEM GO to Symptom Chart. P1837 Transfer Case Rear Shaft Speed Sensor Circuit Failure GEM GO to Symptom Chart. P1838 Transfer Case Shift Motor Circuit Failure GEM GO to Pinpoint Test B . P1846 Transfer Case CONTACT PLATE "A" Circuit Failure GEM GO to Pinpoint Test B . P1850 Transfer Case CONTACT PLATE "B" Circuit Failure GEM GO to Pinpoint Test B .

P1854 Transfer Case CONTACT PLATE "C" Circuit Failure (GEM Only) GEM GO to Pinpoint Test B . P1858 Transfer Case CONTACT PLATE "D" Circuit Failure (GEM Only) GEM GO to Pinpoint Test B . P1866 Transfer Case Maintenance Required (GEM Only) (4-wheel drive operation can be restored by clearing the DTC and cycling the ignition.) GEM GO to Pinpoint Test B . P1867 Transfer Case Contact Plate General Circuit Failure (GEM Only) GEM GO to Pinpoint Test B . P1874 Automatic Hall Effect Sensor Power Circuit Failure GEM GO to Symptom Chart. P1875 Automatic Hall Effect Sensor Power Circuit Short to Battery (GEM Only) GEM GO to Symptom Chart. P1891 Transfer Case Contact Plate Ground Return Open Circuit GEM GO to Pinpoint Test B Your best bet , take it to a qualified repair shop

Apr 04, 2017 | 2002 Ford Explorer

1 Answer

1989 ford truck f350 diesel. head lights,hazard lights, and horn have power and work, batteries are charged but truck will not crank. when i put key in and turn the key over nothing happens....no buzzer,...


1989 f250 4x4 lighting problems. i replaced the floor mounted dimmer switch ,the lights worked fine for an hour untill i turned them off.Now the lights will not turn back on but i have park lights.

Aug 09, 2010 | 1989 Ford F 350

2 Answers

How to tow 1999 F250 Super Duty SuperCab XLT 4x4, 7.9 Turbo Diesel V8 engine standerd


you should be able to tow it with the transfer case in the nuetral position.

Jun 09, 2010 | 1999 Ford F250 Regular Cab

2 Answers

I have a Ford F150 that I engaged into 4L. Now I am trying to engage back to 2H and it is not engaging back. The 4x4 is controlled from the inside of the truck. The controller doesnt feel like there is any...


The switch could be bad, but if you cannot select 4H or 2H, I would think the shift motor in the transfer case is the issue.
This is assuming when you posted "control switch be bad", that you have an ESOF ( Electronic Shift on the Fly ) system.

Some times the Shift motor in the transfer case hangs up, and tapping the back of the transfer case cures the problem. The other thing could be the connector on the transfer case is corroded, remove the connector, and check it for water and other junk, clean if necessary.

You can remove the switch from the dash, and check the resistance on it.
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If you secure the truck ( chock the wheels, parking brake, etc ) and having someone turn the ESOF switch from 4L to 2H or 4H, while tapping on the transfer case, this would be a good place to start.

Feb 23, 2010 | 2003 Ford F150 Regular Cab

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

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