First big snowfall of the year, so I lock my hubs, pull out of the garage, and hit my 4x4 button. The rear clicks and the light does not come on. This happens like clockwork every year! The first time I try to use my 4x4 in the snow, it does not work... And of course it worked perfectly fine a week ago. Looks like I will be pulling the shift motor tomorrow or Wednesday and fixing it. :rolleyes:

I hate that...How many times have you had your shift motor apart? I have an original 1st gen unit. The new ones are slightly different. Even after the 3rd time I had my shift motor apart I still had to occasionally tap on the cover. Tapping helps create a "Better" connection between the geared position sensor and the wires on the cover...

WOW ... The same thing happends with me. I'm really sick of it no. I think I will breakdown and buy a new one. www.clearlights.com has then on sale for like $250. Its some money but right now I would love to have a dependable 4 wheel drive system. After this, NO MORE ELECTRONIC 4 wheel drive ...aahhh. :mad:

I have probably had it apart 3 or 4 times now, not counting this one. I will try tapping the cover first to see if that helps, but if not, I'll just pull it and give it the usual contact buffing. I've gotten pretty good at the whole process... I can usually get it out, repaired, and reinstalled in under 45 minutes.

I just wanted to correct myself, I just went and checked and www.clearlights.com has brand new shift motors for $179.95, I will definatley be ordering that ASAP ....

It says they come with a 12 month warranty... With my luck I'd end up having to pull it again right after the warranty ran out! :D If I wasn't getting rid of the Ex in about 6 months, I might spring for one of those.

When My shift motor fails to move (and I hear the relays clicking in the rear) I break out a meter and check the shift motor wire harness. If it registers ok for all 2H wire combinations then I tap on the cover. I have found the spring contacts under the cover don't make the best connection all the time (sort of like when you have jumper cables on a battery and you need to reposition them to get better contact). My shift motor works now, but it isn't snowing yet..:D

Think I have found the secret after doing mine a couple of times on my 92. Last time I decided to "run the motor in" by removing the gear. This would allow the motor without hitting the stop. Found the motor drew over 4.5A with no load even after a cleaning and lube. Worked the scintered bearings with tranny fluid and after more running the current dropped to less than 3/4 amp. Simple test is to put a brake light in series with the motor. If it will run, it will work in the vehicle. The motor is driven electronically. High currents will cause it to shut down

That's good to know :)... I wish I had a decent meter. Mine is ok, but only reads low current (mA). :(
Next time I have my shift motor apart I will have to pay extra attention to the end bearings. I did shoot some spray lithium grease in them and the motor seamed to work ok (but without knowing the draw I can't tell)

Well I fixed it this afternoon. So far it is working. I really should do this in the summer... Being under a truck after it was just driven in the snow is not fun! :p At least I have my 4x4 back.

How'd you end up fixing it?

The usual... Took it apart and gave the contacts and brushes a light buffing.