Dismiss Notice



Register Today It's free! This box will disappear once registered!

BWM Brown Wire Mod 3rd Gen

Discussion in 'Modified 2002 - 2005 Explorers' started by P. doggy, September 10, 2007.

  • Searches ExplorerForum.com
    1. lkreykes

      lkreykes New Member

      Joined:
      June 5, 2013
      Messages:
      43
      Likes Received:
      0
      Trophy Points:
      6
      City, State:
      Northern Michigan
      Year, Model & Trim Level:
      2005 Explorer XLT 4x4 4.0
      I'm just assuming the button is in the same spot as mine, but I might be wrong. Check the owners manual, it should tell you how to disable it. You could also look for the ABS fuse and pull it, which will disable any safety traction features
       
    2. Support EF

      Join the Elite Explorers for $20

      Explorer Forum has probably saved you that much already, and will continue to save you money as you learn how to diagnose fix problems yourself, and learn which modifications work without having to experiment on your own. Elite Explorer members see practically no ads, can add their own profile photo, upload photo attachments in all forums, and Media Gallery, create more private Conversations, and more. Join Today. Your support is greatly appreciated.


      to hide adverts.
    3. 96firephoenix

      96firephoenix Active Member

      Joined:
      March 14, 2015
      Messages:
      552
      Likes Received:
      39
      Trophy Points:
      38
      City, State:
      Indianapolis, IN
      Year, Model & Trim Level:
      2002 Ford Explorer XLT
      hey all... my ABS lost a sensor, so I've got all-time control-trac.... I'll be doing this mod soon-ish. I'm a technical writer by trade, so I'm good at writing instructions... I will document this process with pics and any notes on the original post... just wanted to bring this up - Rick had offered to host some pics locally so they would not get lost. I'm more than willing to make this possible on my end when I am done.

      Update 3/28: I'm trying to do some fancy wiring on this - possibly to the point where a secondary switch is not needed, but at the very least, trying to use a push-button switch and some relays. instead of a toggle switch.
       
      Last edited: March 29, 2015
    4. fordfan401

      fordfan401 New Member

      Joined:
      March 30, 2014
      Messages:
      17
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Rhode Island
      Year, Model & Trim Level:
      2004 Ford Explorer XLT
    5. Jmedina613

      Jmedina613 New Member

      Joined:
      January 29, 2015
      Messages:
      42
      Likes Received:
      2
      Trophy Points:
      8
      City, State:
      Clermont Florida
      Year, Model & Trim Level:
      2002 Ford Explorer XLT
      This guide is really hard to follow without the pictures. Atleast for me. Can anybody give me a list of the exact things i need to complete this project?
       
    6. Jmedina613

      Jmedina613 New Member

      Joined:
      January 29, 2015
      Messages:
      42
      Likes Received:
      2
      Trophy Points:
      8
      City, State:
      Clermont Florida
      Year, Model & Trim Level:
      2002 Ford Explorer XLT
      Video!

      Hey everybody instead on doing the BWM I just pulled out fuses #17 and #18 thanks too Limited02

      here are the results!!

      http://youtu.be/l_1bIiD9E7E

      this is just a demo, im going to take it out later and have some real fun with it.
      Guys it is so freaking fun!!
       
    7. Limited02

      Limited02 Well-Known Member

      Joined:
      November 1, 2006
      Messages:
      3,593
      Likes Received:
      5
      Trophy Points:
      48
      City, State:
      Gardner, KS
      Year, Model & Trim Level:
      '02 Limited V8
      Nice! Looks like a fun place to play!
       
    8. Number4

      Number4 "I'm counting to 3, then I'm getting your dad." Elite Explorer

      Joined:
      March 16, 2013
      Messages:
      3,776
      Likes Received:
      96
      Trophy Points:
      58
      City, State:
      Woodstock, GA
      Year, Model & Trim Level:
      04 Ford Explorer 4.6l
      Another video comes up after yours of a dude in his Explorer rolling while doing this. lol watch out for ruts and bumps! It was a second gen though.
       
    9. engineeering

      engineeering Active Member

      Joined:
      July 3, 2014
      Messages:
      198
      Likes Received:
      1
      Trophy Points:
      18
      Year, Model & Trim Level:
      06 explorer xlt 4x4
      He fellas. I think I came to the right place. I did a Manual Transmission swap into the 3rd gen and I've got the 4x4 Lo function working but the 4x4 clutch isn't working yet. I am trying to figure out what the BLACK wire is (the one not going to the transfer case motor). See the photo below. Is this BLACK WIRE just to ground? (sorry guys... already sold my 3rd gen parts and can't remember where that dang wire goes and my photo doesn't show it). If you have a 3rd gen... a quick look for me would be a big help.

      Thanks!!

      [​IMG]

      FYI....
      I've wired up the 99-01 AWD Explorer transfer case to the new manual trans.... which seems to have all the same functionality... but stuck on the last two wires (this tcase has 2 speedo sensors (green/blue/grey) wires as well which got me confused temporarily. Think I'm almost there.


      SOLVED MY OWN QUESTION.... black wire is ground. See my manual swap thread for full wiring details (with 2HI bypass switch for AWD button operation)
       
      Last edited: March 10, 2016
    10. tuik

      tuik New Member

      Joined:
      February 19, 2016
      Messages:
      15
      Likes Received:
      0
      Trophy Points:
      0
      Year, Model & Trim Level:
      2003 Ford Explorer xlt
      I've read this won't work on AWD V8's. I have a V6 AWD with three buttons, AWD, 4HI, 4LO in my 2003 Explorer. Can I do this mod with my V6 AWD?
       
    11. engineeering

      engineeering Active Member

      Joined:
      July 3, 2014
      Messages:
      198
      Likes Received:
      1
      Trophy Points:
      18
      Year, Model & Trim Level:
      06 explorer xlt 4x4
      yup. You can. Can't see why you can't with the V8s... but I am not as familiar with their tcase.

      I'm not sure where the brown wire is in the CAB. But I have an 06 GenIV and I tapped into it with a water sealed relay next to the transfer case.

      ps. In theory... any AWD models (clutched transfer cases) should work. All you need to do is put a relay inline with either the hot wire or ground to disengage the clutch (usually brown hot or black ground). The rest regarding tap-in locations, switch placement, etc is all up to your preference and vehicle type.
       
    12. tuik

      tuik New Member

      Joined:
      February 19, 2016
      Messages:
      15
      Likes Received:
      0
      Trophy Points:
      0
      Year, Model & Trim Level:
      2003 Ford Explorer xlt
      Read this whole thread, and I have a NEW question. I am doing the mod on my 03 Explorer, found the BW on passenger side. Connected the relay, and I have a lighted switch. Problem I am at is, where can tie in to get the power for my lighted switch? This mod doesn't have pics that look like mine. I have my center console out, radio out. But I don't know what wire to tie into for power?
       
    13. tuik

      tuik New Member

      Joined:
      February 19, 2016
      Messages:
      15
      Likes Received:
      0
      Trophy Points:
      0
      Year, Model & Trim Level:
      2003 Ford Explorer xlt
      Also, I ran my ground for the switch to the metal bracket on the passenger side, below the glove compartment, just next to the center console. Instead of tieing into some wire. Should be fine right?
       
    14. engineeering

      engineeering Active Member

      Joined:
      July 3, 2014
      Messages:
      198
      Likes Received:
      1
      Trophy Points:
      18
      Year, Model & Trim Level:
      06 explorer xlt 4x4
      I'd say so :) There isn't much current to engage the relay there... worst case (if the ground is/goes bad) the relay won't engage and you'll know. Won't happen though...
       
    15. engineeering

      engineeering Active Member

      Joined:
      July 3, 2014
      Messages:
      198
      Likes Received:
      1
      Trophy Points:
      18
      Year, Model & Trim Level:
      06 explorer xlt 4x4
      I would grab the power off teh radio red power wire (I think it's a bit larger gauge than the rest.. but I'm not sure and won't know till I do my new radio later this month...LOL).

      You could grab the power from just about anywhere (cigarette lighter, lighting power for floor shifter, etc)... but the radio will have some capacity and it is auxiliary (key in ignition required) power so if you leave the lighted switch on... it won't kill your battery when not driving (would probably take weeks to kill it cause it doesn't draw much power at all).
       
    16. tuik

      tuik New Member

      Joined:
      February 19, 2016
      Messages:
      15
      Likes Received:
      0
      Trophy Points:
      0
      Year, Model & Trim Level:
      2003 Ford Explorer xlt
      Thank you for the response :)
      Is anywhere with a red wire a "power" wire? My radio is stock and the wires that go to the harness are pretty small. Not even sure I seen a red wire lol. I tried testing my switch to see if it works by touching the power wire to a 12 volt battery, and attaching the ground to metal. But my switch didn't light up. Is something wrong with my switch, or is this not a way to test it?
      And just to be positive, I ran the two spliced wires into the relay, ran a ground to the relay, and have one wire left that will go to the "load" on the switch. This is correct right? Sorry if the questions are simple, but I'm NOT any good at electrical.
       
    17. engineeering

      engineeering Active Member

      Joined:
      July 3, 2014
      Messages:
      198
      Likes Received:
      1
      Trophy Points:
      18
      Year, Model & Trim Level:
      06 explorer xlt 4x4
      Sounds like you got the right idea. I would double check your relay diagram and make sure it is correct. Also... for your lighted switch... double check that diagram as well and make sure you have 12v to it.
       
    18. tuik

      tuik New Member

      Joined:
      February 19, 2016
      Messages:
      15
      Likes Received:
      0
      Trophy Points:
      0
      Year, Model & Trim Level:
      2003 Ford Explorer xlt
      Yep, it looks like I found the right wire for the power to the switch. I did some research on the wiring. BUT, now that I have everything hooked up, My shifter won't move out of park. It is stuck there. The switch engages the relay because I can hear the relay when I click the switch. But why is my shifter now stuck in park? And it isn't the steering lock either. I don't get it. I spliced the brown wire in the small group of wires. Is there another brown wire, and maybe I clipped the wrong one?
       
    19. tuik

      tuik New Member

      Joined:
      February 19, 2016
      Messages:
      15
      Likes Received:
      0
      Trophy Points:
      0
      Year, Model & Trim Level:
      2003 Ford Explorer xlt
      Or could this be because I have the two ends of the BW backwards on the relay? I did make sure I connected them to the right leads (87a & 30). But this thread doesn't say which of the two wires goes onto which lead. And there isn't any pics for me to see.
       
    20. tuik

      tuik New Member

      Joined:
      February 19, 2016
      Messages:
      15
      Likes Received:
      0
      Trophy Points:
      0
      Year, Model & Trim Level:
      2003 Ford Explorer xlt
      Ok I'm really getting worried now. I reconnected the original wires to see if I could get my shifter to move and it won't budge at all. I don't understand what is going on??
       
    21. engineeering

      engineeering Active Member

      Joined:
      July 3, 2014
      Messages:
      198
      Likes Received:
      1
      Trophy Points:
      18
      Year, Model & Trim Level:
      06 explorer xlt 4x4
      I wish I could be more help but I'm not sure the details/symptoms you're having.

      If it makes you feel better... when I wired in my tcase (from scratch) I got every wire wrong a few times... when I got it right.. worked fine.

      My guess... you are not in neutral or park. Make sure you are in one of those gears or the module won't power anything
       
    22. tuik

      tuik New Member

      Joined:
      February 19, 2016
      Messages:
      15
      Likes Received:
      0
      Trophy Points:
      0
      Year, Model & Trim Level:
      2003 Ford Explorer xlt
      Lol, yes trial and error! I did some troubleshooting and searching on internet. I found that the brake light switch will cause this if its bad. So I decided to go through all of my fuses and see if any were blown, in particular the brake light switch. Found a blown fuse, I can't remember the name right now, but it was something like shift/gear release. Anyway, I'm positive it is my problem. No need to replace the brake light switch :)
      So, back to my original question (one of them lol)... Do BW going to the relay need to be in a specific order? If so, which goes on my relay lead 87 and which on 30?
      I should be good to go after this. I HOPE LOL!
       
    23. engineeering

      engineeering Active Member

      Joined:
      July 3, 2014
      Messages:
      198
      Likes Received:
      1
      Trophy Points:
      18
      Year, Model & Trim Level:
      06 explorer xlt 4x4
      I'm in my car and about to go for a hockey game... min time. Lol

      You need to check the relay diagram... there are posts for power to go straight through when switch is not on... then when switch is on... it should "switch relay to off". Essentially this mod uses the relay to disengage power (rather than engage power). My guess is it is just backwards.

      Check my reverse light diagram to get an idea. In general... the "normally on" is the in cab switch (your ecu power to tcase clutch)

      Sorry I can t be more help... Phone sucks
      [​IMG]
       
    24. engineeering

      engineeering Active Member

      Joined:
      July 3, 2014
      Messages:
      198
      Likes Received:
      1
      Trophy Points:
      18
      Year, Model & Trim Level:
      06 explorer xlt 4x4
      OK. . Just popped my hood to look at a relay

      I'm guessing..

      Cut brown wire. Put both ends to 30 and 87a

      Leave 87 unused

      Put your switch power to 85

      Put your small aux ground to 86

      Happy modding
      (And thank the relay Co for printing a diagram on the top. Lol)
       
    25. engineeering

      engineeering Active Member

      Joined:
      July 3, 2014
      Messages:
      198
      Likes Received:
      1
      Trophy Points:
      18
      Year, Model & Trim Level:
      06 explorer xlt 4x4
      Ps. Also just found my spare key under my hood.. double score (must have lost it there last time I was tinkering g)
       
    26. tuik

      tuik New Member

      Joined:
      February 19, 2016
      Messages:
      15
      Likes Received:
      0
      Trophy Points:
      0
      Year, Model & Trim Level:
      2003 Ford Explorer xlt
      Lol on the spare key :) Those things are expensive, awesome find!
      I was able to replace the fuse and my shifter now works great. I think I crossed a wire when I was searching for a power wire on accident. Problem solved though.
      I went through my connections and gave it all a try. IT WORKS! My lighted switch will light when I turn it on, meaning the auto 4x4 is on as well. But turning off the switch turns my Explorer into two wheel drive :) So happy this is done. Now hopefully I won't be hearing that noise anymore when turning from a stop, and I can save my clutch packs.
      Thank you for all of your help! I really do appreciate your kindness :) Now I need to fix my sticking ignition :( Any chance you know of a thread on that? lol
       

    Share This Page







    We Support Our Troops!