Hi all been a while since I posted on here but I got another pain in the butt problem with my esplorer. I had the 4x4 working great for a long time changed to manuals as per suggestion here replaced the actuator motor and all was good. I put my truck up for the summer because I drive my stang in nice weather. when I got it ready for the winter this fall the 4x4 wouldsnt work. I used some elctronics sleaner on the connectors to the motor and tapped it with a hammer the old starter fix and all was ok. Until day before yeasterday when I needed the 4x4 for the first time snow and all. it would not engage. I looked at it and had the misses hit the button while I was under the truck and I could here the electric motor clicking as if it were trying to go into 4x4 but it dod not go. I think maybe the transfer case needs new gear oil as I have never changed it but maybe you all could help me out. THanks in advance. 92 exploer sport 5 speed manual with warn manual hubs

Len

Sounds like the shift motor got dirty. The tech library at www.therangerstation.com has an article about cleaning the shift motor. I expect it's worth a try.

And if you change the fluid in the t-case (probably not a bad idea, since it's probably never been done), note that it takes Mercon ATF, not gear lube.

Try tapping gently with a hammer :)