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How to: Rebuild 4X4 Shift Motor

Discussion in 'Transmissions & Transfer Cases' started by Brain, December 20, 2004.


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    1. 94ExploderSport

      94ExploderSport New Member

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      well I guess no one else can figure it out either...
      I just said fukit too the motor off and just switch it manually with pliers
       
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    3. alaskan155

      alaskan155 New Member

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      just like to bump and say thankyou, i just did this to my 2000 ranger and it works better than new,

      all i did was take apart the electric motor and chuck the center part in a drill, then ran some fine sand paper around it until it was nice and clean, same with wear the brushes go,

      then i install some new springs(just a random one i had laying around, i cut it to length for the brushes), and cleaned out the magnet motor casing and re greased the brass bushing.

      the only difference i found in the 2000 and the guide is the contact that tell the computer what gear the transfercase is in is a sealed unit, you can only adjust it by the 3 torx bolts.

      mine had some water intrusion inside the motor, but it seams to work better than new, shifts alot quicker than what it did before it died.
       
    4. alaskan155

      alaskan155 New Member

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      the contacts need to be cleaned, where the 3 wires go to, it was sealed in my 2000 but i bet they are servicable like the guide shows:thumbsup:
       
    5. mountainfish

      mountainfish New Member

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      Thanks!

      This thread fixed my problem. Thanks for the photos and detailed instructions!:thumbsup:
       
    6. lchambers

      lchambers New Member

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      low range problem

      My 1991 Explorer has a problem with low range. 4 wheel drive in high gear works great. But when the light comes on indicating it's in low range, it acts like it's in neutral. What's the problem?
       
    7. lchambers

      lchambers New Member

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      Could it be that stop bushing causing the problem?
       
    8. 87xjmike

      87xjmike Member

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      Does anybody know the OD of the plastic stop bushing or the equivalent OD to the rubber hose that has worked as a stop bushing?
       
    9. Cecil Hollifield

      Cecil Hollifield New Member

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      Great job on how to fix 4 wheel drive. Thanks a bunch
       
    10. OneofMany

      OneofMany Active Member

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      I sometime have an issue with getting stuck in 4x4 or 2x4. So far it has always engaged or disengaged itself after a little driving. I figure it is the shift motor stop bushing- I have manual hubs.. The Switch lights work normal but once in a while i see a dimly lit 4hi light on. My question is where do i need to make these alignment marks the OP talks of. It seems unclear in the post.
       
    11. wojt_sgs

      wojt_sgs New Member

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      Hey there! So I fixed my plastic bushing, my 4x4 trunk relay is working properly(did test - led is flashing 4-5 times), motor is working fine when I connect it to 12V, gears move as should but pressing 4x4 does nothing at all. It makes clicky sound in relay and underneath car but nothing else. I did manually change to 4H and moved shift motor by connecting to 12V to 4H position, bolted shift motor to its place, it was indicating 4x4 but I couldnt change it to 2H. Any ideas?

      [​IMG]
       
    12. DeRocha

      DeRocha NEX Vice President Elite Explorer Moderator Emeritus

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      The relay's clicking and failing to energize the shift motor could be an indication the shift motor gear is not indexed correctly. It appears you have a new style position sensor. Did you flip it over and verify the contacts are in good condition? If so have you tried re-installing the shift motor 1/2 way between 2H and 4H? Yes the fit will be sloppy, but that's the point. Putting it in no man's land will allow the 4x4 computer to see that it's in No mans land and shift it up to 4H or 2H where it will stop in the correct position. If you try to re-install the geared position sensor in EXACTLY 2H it can be very difficult to line it up (which can cause it to be outside of the operational range and do nothing).
       

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