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97 ford 250 transfer case won't engage,new case and decoder.all connections correct Electrical?

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First thing you didn't post your engine size and automatic transmission or manual and there are different parts for all engines transfer cases ,there could be a vacuum leak or an electrical problem with a fuse ,plug ,or actuator, first check the fuses associated with all the components, next you must check all plugs that they are clean and are not oxidized or corroded,next check your actuator [multiple ones ]4wd hub locking solenoid[multiple ones]4wd actuator fork [same as above]transfer case control lever[]transfer case motor , shift fork insert,4wd switch inside , transfer case switch on the case most times there is a vacuum leak in a line or the transfer case motor ,or the case switch you must start with each component ,and narrow it down write everything you do down so you can eliminate possible causes you will need a handheld vacuum pump ,a volt meter, and a long piece of vacuum hose to fit in your ear to search for the leak around the lines and hubs ,yes I just said that , this works like a stethoscope the doctors use when you pass over a vacuum leaking hose or component you will hear the hissing noise much easier using the hose and cotton in your other ear because you are isolating the area you can hear from instead of trying to listen to the whole engine running and trying to find a leak with outside noises , belts, pulley bearings , etc. ok so be patient and don't go ballistic when you find out that you changed a whole bunch of stuff that you didn't need to because of a simple hose leak or a bad switch all vehicles need to be maintained and those area's are fluids & filters , ignition [ plugs coils distributor cap & rotor if applies] vacuum hoses, and vacuum actuated valves and solenoids , belts and the most important one all electrical connections must be cleaned and tight and free of corrosion[starter , battery , power distribution box , all fuses and relays , fuel system [ throttle body cleaning gas filter in tank screen attached to the fuel pump housing on the bottom any one of these can cause you a boat load of problems as vehicles get older,// yours is 22 - 23 years old by build date so you must go to each area and do preventive maintenance to keep an old girl running and always remember that yes a vehicle runs on gas/diesel , but its the electrical sensors and vacuum lines that control it , voltage signals as well as vacuum inches are measured by the P.C.M. and other controllers[4wd] when it doesn't see specific parameters it will keep trying to adjust it until that individual failure happens prematurely from a broken line or corroded connection so your learning right now so take it all in as a lesson ok good luck stephen PS. go to rock and look up your truck and all the parts for it so you can see what your looking for it will make it easier for you

Posted on Dec 03, 2019


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Posted on Jan 02, 2017



  • 16 Answers

SOURCE: 97 F-250 Transfer case shifter linkage broken!

97 f250 is it light duty - newer body style or heavy duty old body style??.. IF its older try 93-97 if its newer try-97-00

Posted on Feb 10, 2009


  • 29 Answers

SOURCE: 2005 Ford F150, 5.4L V8, 4x4; The transfer case

Encoder motor located on the transfer case is usually the problem. It is the motor that shifts the transfer case.

Posted on Sep 28, 2009

Testimonial: "Will look into this and report .Thanks so much"


Steve S

  • 984 Answers

SOURCE: 2002 ford f150 4x4 manual transfer case vacum

The vacuum shift solenoids have power to one side of them at all times.
The GEM applies ground to them, to activate them, after the shift on the fly position confirm from the trans case.
The power to both should be on the White w/ Light Blue stripe wire.
Ground to them ( from the GEM ) is
2WD : Gray w/ Black stripe wire
4WD : Red.

The only TSB I know of is for the 04-06 MY trucks, for the IWE solenoids ( the kind without the water shield ).

Did you jack up the front end ( and support correctly ) turn the key to the run position ( do not start ), and shift into 4WD, and check the front drive shaft ?
If the shaft still turns, the problem is in the transfer case, if not you are looking in the correct place.
The GEM will not signal a vacuum solenoid until the transfer case has shifted into 4L or 4H ( 4 switches that are the return signal to the GEM ). Could be a problem with the connector on the transfer case ( think it is a 8 or 10 pin connector ) to the contact plate position switches in the trans case.

There is a manual front ale cable, but I would think you would want to confirm why the GEM is not signalling the shift solenoids, prior to replacing them
Posilock make a kit for the F-150

Posted on Dec 12, 2009


  • 1 Answer

SOURCE: 1995 ford F-250 diesel 4x4 automatic hubs won't engage.

i have a 1995 7.3 dont rev up over 2 grand

Posted on Jan 29, 2010


  • 5 Answers

SOURCE: 2003 Ford explorer transfer case and shift motor problem

need more information on this one.

Posted on Feb 17, 2010

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