I just changed out my

Oct 24, 2009

- okay the blk is ground the blk/red is instrument illumination input , the dk grn is message center switch to cluster and the lt. grn is also message center switch to cluster. so the blk gets ground to chassis the blk/red get power from illumination circuit and the two green wires dk and lt. will go to the over head console. not sure what you have because there is an early build and a late build but the cluster is from an early build because of the color of those wires. now i need to know if you have that earlt or late. before or after 03/2002 and if they are both early build the colors will be the same if not the colors are different on the other end.

Oct 24, 2009

- yea i looked at the schematic and there is no way to tell until i know the build date. you can get it of the door tag. let me know and i will research it for you and get the it working,

Oct 24, 2009

- okay leaving the shop in a little while let me get home and do some research to see if we can get this done.

Oct 30, 2009

- yea from what i can see it is not going to be possible without it coming factory. the harness and bcm is different so without change a buch of stuff including the harness itself you might not be able to do it. sorry for the bad news and i hope you find a way.

Oct 31, 2009

- well what i have found in the alldata program i have for the shop is it is a data transfer from the body control module(bcm) and the cluster. and there reason you didn't have the other connector is because that option to transfer the data from bcm to cluster was not in that bcm and everything first goes through the bcm to manulate the data into something the cluster can use.

now this is all from alldata and they get all there info straight from the dealer and all the schematic's are dealer schematic's so this is what i base my opinion on. not i specailize in electical and know this could be done... but how far are you willing to go and how are your skills with electical? this may require thing like reprogramming the bcm and is something me nor you can do and only the dealer can and they wouldn't even be bother with this stuff because of liabilty.

now what you have in your truck and not have i don't know exactly because that was unclear because of the build date's and that there are two totaly different systems and get's confusing because i don't have in front of me. this is why i said i had to bow out of this one because i don't feel we could get this done over an email based forum. now if i was allowed to ask for your # or call you then i may have said or felt totaly different. there is just so much man and i really wish i could of helped you and still do. i love stuff like this exspecaily when i haven't done this i want to know what it takes to do it. because i will have that knoldge under my belt. not that this is something i would do a number of times but even once it would be worth me to figure out. i really did my best with what you could tell me and what i can see in alldata. but again because of two systems and two build dates stuff will get confusing and things good be damaged and cost alot of money to fix.

if you still want to try go to the truck you got the cluster out of and compare it and the bcm to your truck along with the harness and see the differences. that is were i would start. the plugs and harness and build dates are very important.

one more thing i take pride in my feedback (thumbs up) and i understan i couldn't help but i gave it a good amount of time and a good try with the info i had so if you could reconsider that. that would be great.

good luck man

Oct 31, 2009

- thanks man and i wish it could be simpler.

Oct 23, 2009

- I'am a 25 year veteran Ford dealer tech and am confident of this info. Good luck on this.

Oct 30, 2009

- you never got this wired up did you?

Oct 30, 2009

- give it up, u can't do this short of an entire new wiring harness.

Nov 06, 2009

- I DON'T THINK U WILL FIND THE SOLUTION YOU CHOOSE WILL WORK, GOOD LUCK HERE.

Oct 24, 2009

- According to my Haynes repair manual 2001 and later models have a separate control module just for the 4X4 system that is located behind the right front passenger kick panel.

Replacement of the 4WD control module does not require programming using the Ford scan tool on this vehicle. Vehicles built after 03/04/2002 with the 11th digit of the VIN being (U) or vehicles built after 03/11/2002 with the 11th digit of the VIN being (Z) require a different module than those built before these dates. The modules are not interchangeable though the harness connectors will plug into either of the modules. The modules have different internal designs. The 4WD shift module is located forward of the glove box, under the passenger side of the dash.

1. Check the resistance of the magnetic clutch coil at the transfer case measuring between terminal 16 and terminal 11 of the shift motor connection. Terminal 16 connects to a Brown (BN) wire on the harness and terminal 11 connects to a Brown/Yellow (BN/YE) wire on the harness. Resistance should indicate a reading of 2.5-3.0 ohms.

2. Use a scanner to try and command the 4WD clutch on. If this is possible, monitor the voltage on the BN wire while increasing the command on the clutch. If there is low or no voltage to the clutch no matter what the command, check the powers and grounds to the module.

3. The Four Wheel Drive (4WD) module is located behind the glove box area.

A. C281a pin 1 Black/White (BK/WH) and pin 2 White (WH) should be battery voltage at all times.
B. Pin 9 Violet/Orange (VT/OG) should be battery voltage with the key on.
C. Pin 10 Orange (OG) should be battery voltage with the key in the crank position only.
D. C281b pin 16 Grey/Yellow (GY/YE) should be battery voltage with the key in the run position.

3. The grounds are C281a pin 7 Black (BK) and C281b pin 2 Black/Light Blue (BK/LB).

4. If the powers and grounds are OK, replace the 4WD module. Be sure to get the correct module, the early and late build modules will plug in but are not interchangeable.
The powers and grounds have to be checked or rechecked at the pins that I specified , to find the problem with the system. Usually when the problem is not the module it is the clutch coils or the module's circuits or a connection. Checking the pin outs would eliminate this and must be done!
There are 2 other things to check that would be tire stagger if there are worn or different size or diameter tires on the vehicle it will cause certain problems , but I don't think it will result in just a flashing light usually there is a drag felt when driving.

The other thing is a bad ground at the transfer case. Ford uses a copper gasket between the transmission and transfer case the purpose of this is to facilitate the ground to the transfer case if the gasket was replaced (with a paper one) or heavily siliconed the ground could be insufficient.

Good luck.