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1996 4.0 V6 4x4 w BW 4405 t-case. No 4wd.

Discussion in 'Transmissions & Transfer Cases' started by Aarnio, December 22, 2017.

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    1. Aarnio

      Aarnio New Member

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      Ford Explorer 1996 4.0 V6
      Hi folks,

      The guy that sold the car said everything working and during the short test drive last summer, yes, and apparently not...

      Well, been fixing this and that. Brakes, brake lines, driver door harness wirings (mirrors, door locks, power windows)

      But I still have no 4wd. Pretty annoying with 4x4.

      Started with blinking 4wd lights with 4wd Auto when I thought I really could use 4wd. With 4wd Low I could hear the clunk from t-case. The tf-case shift motor working obvioysly.

      Bought an OBD interface. Scanned with FORScan. Got code for tf-case rear shaft sensor. Replaced that. Blinking dash lights went away but then code for front shaft sensor. Replaced that.

      Now dash lights not blinking, 4wd Auto light and 4wd Low light come up accordingly and t-case gives the 'clunk' when swithing to 4wd Low.

      New codes from scan:

      P1804 - Four wheel drive high indicator circuit failure
      B1302 - Accessory delay relay circuit failure
      P1820 - Transmission transfer case low to high shift relay coil circuit failure
      P1828 - Transmission transfer case high to low shift relay coil circuit failure

      Any advice would be appreciated.

      Cheers and Merry Christmas,

      Aarni
       
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    3. Aarnio

      Aarnio New Member

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      Would the 'brown wire mod' bypass all this and force the system into 4wd? Assuming the t-case is ok. All I really want is the 4wd low to work _when_ I want it.
       
    4. Aarnio

      Aarnio New Member

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    5. Aarnio

      Aarnio New Member

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      Or rather like this?

      Position 1&2: normal, same as uncut and GEM connected.

      Position 2&3: cut, GEM disconnected, aux power to TCCC.
      2wd = 100%4wd, 4wdAuto = 100%4wd, 4wdLow = 100%4wdLow.
      HAL-sensors, TOD-relay and GEM bypassed.

      spdt-on-on-4forced.jpg
       
    6. Aarnio

      Aarnio New Member

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      After some reading, I got GEM and TCCC wrong in the previous image, they are apparently viceversa. And that's why I couldn't quite understand it. This should be it? With the extra switch off (position 1&2 connected) it's normal and same as not cut. Switch it on (position 2&3 connected and GEM + TOD disconnected) and you have full 4wd all time, high and low. Or could someone please correct me if I'm wrong?

      spdt-on-on-4forced.jpg
       

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