1. It's time for our yearly 2 for 1 Elite Explorer sale! Last day is November 30!

    Right now you can purchase an Elite Explorer membership for $20 and receive a full two year membership!

    Click Here to start your membership!

    If you would like to extend an existing membership for two more years please contact "Rick" through a conversation/private message as I will have to set up existing memberships manually. Thank you and happy holidays!!!
    Dismiss Notice



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

How to: Rebuild 4X4 Shift Motor

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

  • Searches ExplorerForum.com
    1. Glacier991

      Glacier991 EF Tranny Guru Moderator Emeritus

      Joined:
      February 8, 2003
      Messages:
      9,835
      Likes Received:
      7
      Trophy Points:
      48
      City, State:
      Sacramento, CA 95827
      Year, Model & Trim Level:
      1992 XLT
      For those not familiar, when glfrederick talks, it is worth listening. He is one of the boards better (best?) members (a not insignificant number I might add) knowledge wise.
       
    2. Support EF

      Holiday Special through Nov 30! Join the Elite Explorers for $20 for 2 years!

      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 directly to your posts and Media Gallery, create more private Conversations, and more. Join Today. Your support is greatly appreciated.


      to hide adverts.
    3. Arianna

      Arianna New Member

      Joined:
      December 11, 2005
      Messages:
      8
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Bishop California
      Year, Model & Trim Level:
      1993 Eddie Bauer
      You are a Godsend

      Thank you Thank you Thank you. All your information and pictures is excatally what I have been searching for, for a week now. I am so relieved that I can do it myself. Maybe you should write a manual seeing as how the one I have has nothing on what I needed. Thank you so very very much.
      Arianna
       
    4. Arianna

      Arianna New Member

      Joined:
      December 11, 2005
      Messages:
      8
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Bishop California
      Year, Model & Trim Level:
      1993 Eddie Bauer
      Yeah Houston we have lift off!!!! Just got done repairing the shift motor and I have lights on the dash. My 4 wheel is working again. Thanks for all the great info.
       
    5. DeRocha

      DeRocha NEX Vice President Elite Explorer Moderator Emeritus

      Joined:
      July 5, 2003
      Messages:
      6,663
      Likes Received:
      9
      Trophy Points:
      48
      City, State:
      Brockton, MA
      Year, Model & Trim Level:
      '93 XLT 4x4
      Nice work :thumbsup: You just saved yourself several hundred $$... Most shops would only suggest a new shift motor rather than attempt to fix the old unit...
       
    6. rudmann73

      rudmann73 New Member

      Joined:
      December 13, 2005
      Messages:
      2
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Missoula, Montana
      Year, Model & Trim Level:
      1993 Ford Ranger XLT 4x4
      Great pictures of the shifter motor components. It turns out that the plastic bushing, which serves as a mechanical stop on the reverse side of the gear, was my problem. Mine was completely broken and crumbled. My questions is "what can I replace the bushing with and where can I get one?"
       
    7. N7XME

      N7XME Member

      Joined:
      May 7, 2002
      Messages:
      94
      Likes Received:
      1
      Trophy Points:
      0
      City, State:
      Vancouver, WA
      Year, Model & Trim Level:
      94 LTD

      I used a piece of high-temp heater hose of the correct diameter cut to length to fit in the case. Been going strong for over a year since my repair.
       
    8. h3kt0r

      h3kt0r New Member

      Joined:
      December 15, 2005
      Messages:
      2
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Illinois
      Year, Model & Trim Level:
      93Ranger STX & 98Explorer
      Awesome Thread!

      :D


      Just wanted to say thanks and I really appreciate this information. I live in Chicago and really needed my 4-wheel drive to work just to get the truck into the garage as the snow in the alleys remain unplowed. I was searching for the cost of a replacement transfer case just so I'd have an idea of what I might be charged when I came across this website. I read the information and everyone’s tips a few times then crawled under the truck and took care of business. I didn’t need to cut any wires as I did this on the garage floor under the truck lying on my belly. Thanks everybody!
       
    9. JStrider

      JStrider Active Member

      Joined:
      December 18, 2005
      Messages:
      302
      Likes Received:
      0
      Trophy Points:
      16
      City, State:
      North Houston, TX
      Year, Model & Trim Level:
      *RIP* 1993 XLT 4dr 4x4
      Hey... new here... this is a really great site...

      i'm trying to do this repair, and I have already gotten the whole thing off my car, its still attached by the wires, so i'm stuck working under my car but thats beside the point

      i got the torx screws off and have opened the case, but cant get the large gear to come out, it looks like its just press fitted thru the housing but it wont push out, at least not easily.

      I havn't taken apart the motor part, I was hoping to avoid doing that if possible

      whats the best way to get this gear out of the case so I can access the rubber stopper?

      thanks for the help!
       
    10. JStrider

      JStrider Active Member

      Joined:
      December 18, 2005
      Messages:
      302
      Likes Received:
      0
      Trophy Points:
      16
      City, State:
      North Houston, TX
      Year, Model & Trim Level:
      *RIP* 1993 XLT 4dr 4x4
      ok i got the gear out... had to use an extractor, one of those things with the 3 legs that grabs onto something and then you turn a threaded bar i nthe middle and it will push things out... worked pretty good

      now i'm trying to find some tubing to replace the rubber stopper

      another thing i noticed is that the white plastic bit that stays between the gear and the housing(where the gears axle goes thru the housing) is cracked, is this something that needs to be fixed?
       
    11. JStrider

      JStrider Active Member

      Joined:
      December 18, 2005
      Messages:
      302
      Likes Received:
      0
      Trophy Points:
      16
      City, State:
      North Houston, TX
      Year, Model & Trim Level:
      *RIP* 1993 XLT 4dr 4x4
      woooo it works!
      that repair took entirely longer then it should have... but thats alright... cuz it works now and it barely cost me anything

      I ended up using some 1/4 inch ID 3/8 OD vinyl tubing that was by my dads old fish tank

      worked great

      now i just need to fix my sagging door and she'll be good as new!
       
    12. soundaroundyou

      soundaroundyou New Member

      Joined:
      January 1, 2006
      Messages:
      12
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Towanda, Pannsylvania
      Year, Model & Trim Level:
      1993 XLT 4.0
      Parts for shift motor rebuild?

      I am new to the board.
      I was wondering if it would be worth while to have a rebuild kit made? I have a shop here locally that rebuilds electric motors of any type and may be able to either make brushes or pull a size off the shelf that would work. Also could have a machinest make the stop out of nylon, resin, or a metal of some type. New springs could be good also. I would be glad to research this if anyone has an old broken drive motor they could send me. I can use my own in the spring. I would now but it is snowing and I need it! LOL
      I have to say, before I owned an Explorer I really did not have any interest in them at all. I needed a work vehicle, since I totaled my Jeep, and found a beautiful 93 with a standard trans and a 4.0 six engine at an auction and fell in love. It seems that Ford picked up where Jeep left off. My Explorer has fixed every gripe I ever had with my Jeep. I have had to put a few dollars in a new trans, lock out hubs, and a few other needed things, but I am completely sold. I love this truck. It is everything and more that I have ever wanted out of a truck. I love this body style. Sorry guys, I like the later years but, this one is for me. This next year, maybe 2, should be good for her. I plan to customize the interior and then have fun with the outside. I have already started ordering parts. Sorry, I could go on and on. Hope everyone will have a safe any happy new year.

      Chris
       
    13. DeRocha

      DeRocha NEX Vice President Elite Explorer Moderator Emeritus

      Joined:
      July 5, 2003
      Messages:
      6,663
      Likes Received:
      9
      Trophy Points:
      48
      City, State:
      Brockton, MA
      Year, Model & Trim Level:
      '93 XLT 4x4
      Nothing to worry about, the split is a normal part of the white plastic sleeve.
       
    14. DeRocha

      DeRocha NEX Vice President Elite Explorer Moderator Emeritus

      Joined:
      July 5, 2003
      Messages:
      6,663
      Likes Received:
      9
      Trophy Points:
      48
      City, State:
      Brockton, MA
      Year, Model & Trim Level:
      '93 XLT 4x4
      Hi Chris and welcome to the board... I too am fond of the 1st gens ('91-94), although the look of the current Explorer is very sweet (just not alot of off-road mod options)...

      I'm not sure how much interest will be in a shift motor rebuild kit.. Most repairs only require you to dissasseble the shift motor, clean it, and install a new stop bumper (which a length of 5/16" fuel hose or equiv will work). I've never heard of the brushes going.. The Shift motor @ max travel (ie 4 Low) only rotates the gear approx 3/4 revolution in both forward & Reverse so the brushes will last forever.
       

      Elite Explorer members see practically no ads, can add their own profile photo, upload photo attachments directly to your posts and Media Gallery, create more private Conversations, and more. Join Today. Your support is greatly appreciated.
    15. soundaroundyou

      soundaroundyou New Member

      Joined:
      January 1, 2006
      Messages:
      12
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Towanda, Pannsylvania
      Year, Model & Trim Level:
      1993 XLT 4.0
      Shift Motor

      I was thinking the same as you but, thought i would ask. Thanks.

      Chris
       
    16. rudmann73

      rudmann73 New Member

      Joined:
      December 13, 2005
      Messages:
      2
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Missoula, Montana
      Year, Model & Trim Level:
      1993 Ford Ranger XLT 4x4
      gear bushing replacement

      Thanks to the folks who suggested various hose material to replace the gear busing (plastic bushing on rear of the gear). I ended up using a thick walled fuel line hose. Cost was close to nothing, and it seems to do the job. :cool:

      Thanks again to the person posting the great photos of the shift motor assembly. My gear busing was in pieces, and I had no idea where these little chuncks had come from until I had the opportunity to see the photos and read the text :thumbsup:
       
    17. ajax33

      ajax33 New Member

      Joined:
      January 15, 2006
      Messages:
      9
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Dubuque, Iowa
      Year, Model & Trim Level:
      '98 XLT 4WD
      I just wanted to say hi and thanks for the awesome post. I came across this site when I was looking for some help with my '98 XLT...This was an awesome post with awesome pics...and I helped out tremendously. Though on mine the bushing was fine...it was the brushes that needed replacing. Thanks alot!
       
    18. vjam44

      vjam44 New Member

      Joined:
      February 12, 2006
      Messages:
      4
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      langley bc
      Year, Model & Trim Level:
      90 ranger xlt 4x4
      well i tried...

      Broke 2 T-20 bits with the hole, still could not even loosen one screw! Also could not take out single brown wire... no biggie just have to work under the truck. any suggestions??? :confused: :eek:
       
      Last edited: February 19, 2006
    19. prochorus

      prochorus New Member

      Joined:
      February 19, 2006
      Messages:
      2
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Apple Valley, CA
      Year, Model & Trim Level:
      '92 Eddie
      Brown wire removal

      '92 EB that cost me $1.00
      I just pulled my shift motor last night - cleaned and rebuilt it and will reinstall in a few minutes. My problem was a little different than what I've seen in this thread. I had one of the traces on the circuit board corroded to the point that there was no continuity on that circuit. I'll post pics later showing how I repaired it.

      The brown wire comes out very easily after you remove the red plastic retaining ring from the center of the plug. I use a pair of hemostats like an earlier post suggested and it slid right out. There are no tab or catches or anything to worry about breaking it just lifts out. Once removed carefully pry the little black tab around the center pin (brown wire) toward the outside of the plug with a small screwdriver and while holding the tab away from the pin pull the brown wire out the back of the plug. Hopefully this discription is clear enough, I'll post some pics of this too.
       
    20. LBarr2002

      LBarr2002 Well-Known Member

      Joined:
      September 17, 2003
      Messages:
      1,496
      Likes Received:
      0
      Trophy Points:
      46
      City, State:
      Leesville, SC
      Year, Model & Trim Level:
      '91 XLT 4x4, '92 XLT 4x4
      Just did this today. My 4wd problem was intermittent, so I didn't know if it would be just the bushing or not. But, when I got it apart there was no bushing and the pieces of it had been ground up and were all in the main gear and drive gear.

      Now, the reason I posted this:
      To replace the bushing, I used a rubber wire gromet that I had laying around in a assortment. I think it was 1/4 inch and it fits and works perfectly.
       
    21. TheRo0sTer

      TheRo0sTer New Member

      Joined:
      March 13, 2006
      Messages:
      4
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Ellsworth AFB
      Year, Model & Trim Level:
      98' XLT Limited
      Ok I've been reading and reading... Finally I decided instead of reading all 5 pages, can someone tell me how to test my switch and or motor. I found a replacement motor at NAPA for $88 - military discount. But I don't want to pull it all out and find out it was the switch instead of the shift motor. Any help will be much appreciated. It's a 98 XLT Limited.
       
    22. TheRo0sTer

      TheRo0sTer New Member

      Joined:
      March 13, 2006
      Messages:
      4
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Ellsworth AFB
      Year, Model & Trim Level:
      98' XLT Limited
      All fixed the battery disconnect trick worked! Funny thing the switch goes in and out of 4w High with ZERO issues! :confused:
       
      Last edited: March 13, 2006
    23. chonies

      chonies New Member

      Joined:
      February 20, 2005
      Messages:
      10
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      phoenix az
      Year, Model & Trim Level:
      93 xlt
      yeah man did this as soon as i got done reading it and it works perfectly!!!
       
    24. wheelinford22

      wheelinford22 New Member

      Joined:
      March 4, 2006
      Messages:
      4
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Monroe, WA
      Year, Model & Trim Level:
      91' eddie baur
      Hey thanks for the help here, this worked great...saved me some money and took only about 30 minutes from start to finish!!
       
    25. Millette 34

      Millette 34 New Member

      Joined:
      April 3, 2006
      Messages:
      1
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Quebec
      Year, Model & Trim Level:
      Ranger 1989
      would it be possible to lock the 4x4 permanently without changing anything?
       
    26. DeRocha

      DeRocha NEX Vice President Elite Explorer Moderator Emeritus

      Joined:
      July 5, 2003
      Messages:
      6,663
      Likes Received:
      9
      Trophy Points:
      48
      City, State:
      Brockton, MA
      Year, Model & Trim Level:
      '93 XLT 4x4
      Many people have gone wheeling with a broken shift motor. They Just remove the shift motor completely and rotate the selector shaft to the 4H or 4L when they are ready to wheel. When they're done they rotate it back to 2H and everythings back to 2 wheel.. When rotating the shaft you will positively feel the shaft drop into place in each position 2H, 4H, and 4L, so you don't have to worry if you turned it enough...
      [​IMG]
       

    Share This Page







    We Support Our Troops!