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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. DeRocha

      DeRocha NEX Vice President Elite Explorer Moderator Emeritus

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      Sorry to hear you having troubles, but if you're stuck in 4H why don't you just remove the shift motor and manually turn :hammer: the T-Case selector shaft back to 2H? All this info is in the various shift motor threads
       
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    3. CBII

      CBII Active Member

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      Thanks for the reponses guys. I don't hate all Fords more just this one since it's causeing me a ton problems. I'm going to grap another one form the junk, stripe it down and try that.

      DeRocha...Yes I could have manually selected it back to 2wd. However the roads in my area are brutal and the wife needs it to get to work. So having the 4X4 on all the time for now is ok. Oh and I have read most if not all the threads regarding this.
       
    4. DeRocha

      DeRocha NEX Vice President Elite Explorer Moderator Emeritus

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      Have you used a voltage meter to test the wiring harness on the shiftmotor to ensure it reads the correct continuity for 2H, 4H, and 4L? If you haven;t foud the wire info the schematics can be found in Repair info 4x4 system.
       
    5. rikguy

      rikguy Active Member

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      Hey I am pulling the shift motor this weekend. I can hear it turning when I shift into 4 Hi and 4 Low but it doesn't engage. I am hoping that it's just the bushing that goes crappy on the inside. I was wondering, what size rubber hose does everyone use that has replaced that bushing before? I would like to have a piece handy before I have the motor removed. Thanks.
       
    6. shamal

      shamal Elite Explorer

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      Hose size

      Rikguy: I used 5/16" gas line, did not measure the pin. I just wanted a snug fit , the gear pressed in place holds the hose, once installed. If your gear is turning, you might find something else wrong in here, ie you are hearing the motor turn and the gear or shaft stub are damaged. Youll know once you drop the motor down, it's not difficult to see how the system works.
      Good luck
       
    7. rikguy

      rikguy Active Member

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      Thanks Shamal. I'll check things out onoce the motor is out. I'll get the gas line and replace the bushing since I'll have it apart anyways.
       
    8. kmmac1705

      kmmac1705 New Member

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      what is brown wire

      what is brown wire for . If it is messed up will it still work
       
    9. Yellowneckey

      Yellowneckey New Member

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      Now it works great

      I just rebuilt the shift motor. Works great now. What is with the brown wire? What a stupid design. I cut it and added disconnect terminals for next time.
       
    10. djbiker27

      djbiker27 New Member

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      today me and my bro david, bmxunleashed (you guys might know him), worked on my transfer case motor today. it was pretty annoying to get off, but we did. without cutting the brown wire haha :cool: . we took the motor apart and cleaned the combs and everything. we didn't take apart the part with the gears because we didn't feel like it and i didn't think it would be the electronics sensors or anything because my 4x4 button lights don't even flicker. ever.

      so we put it back in and nothing. not even a response. once again just the fusebox in the back making a little click. so that was a bummer. we did get the torx T-20 bit though. the next day we have free time we'll check it out and hopefully fix it.

      i need some diff fluid because it sounds bone dry in there.

      but my truck sounds way cooler with the magnaflow muffler i just got :thumbsup:
       
    11. rikguy

      rikguy Active Member

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      After checking out the motor, it looks fine, even the bushing. It moves when the switch is moved so I must have another problem going on. Back to troubleshooting!
       
    12. travislee91EB

      travislee91EB New Member

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      My shift motor has gone out. Is it a dealer item? I see you are wanting to buy old ones?
       
    13. Reggie32

      Reggie32 New Member

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      Need help

      I've been reading this forum and using it to help me put a rebuilt electric motor on my transmission. I have a 92 ranger with the borg-warner 13-54 transfercase. Everything went fine until I got to the electric plug. The new motor I got has three less wires running to the plug than does the old one. The wires from the other spots on the back of the transfercase aren't in the new plug. What do i do about this, I know two of the wires come from some sort of sensor. Any advise would be good.
       
    14. Reggie32

      Reggie32 New Member

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      error in my last message

      I'm putting an electric shift motor on my transfercase, not the transmission.
       

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    15. DeRocha

      DeRocha NEX Vice President Elite Explorer Moderator Emeritus

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      The electromagnetic clutch wire can be removed without cutting by popping out the wire post retention clip within the wire connector.. See post #24 for a picture..
       
    16. DeRocha

      DeRocha NEX Vice President Elite Explorer Moderator Emeritus

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      It sounds like you have an incorrect shift motor (there are several models of the shift motor for the 1354, but for later years). The old and new wiring harnesses must match up... Take a peek at Explorer Shift Motors
       
    17. CBII

      CBII Active Member

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      Ok so a little update. I replaced the switch on the dash since my fist broke the first one. And yes I felt better after. I also picked up a used shift motor for a song and dance. First thing I did was re-read the rebuild thread here and opened it up. This thing was mint. Hell the little rubber thing was still in great shape. I rotated it anyways just to carefull.

      Ok put it all back and cycled through all the postions worked great. Installed it all and retested it. Worked great. That was just before Christmas. Snow storm started and I "thought" I was perpared.

      Ya NO...friggen thing will not shift into 4wd now. The control module in the back clicks and makes a pile of noises. I think that's a good thing? I can here the motor moving yet still no 4wd. It did actually engage once and stupid me hit the button again and never got any action since.

      This thing has frustrated the hell out of me. I even read the thread about converting them to manuals. However that didn't lead toward a fesible option at this time.

      I do have a question about the control module though. If you by pass it when you install an after market deck would that not eliminate a potential failed part?

      Any other suggestions?
       
    18. CBII

      CBII Active Member

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      More strange happenings with my mysterious 4X4 problem.

      First off she managed to get the 4X4 to engage which was good since the roads where brutal the last few days. So the idea was just leave it until I have time to look at it again.

      So today I'm off I decided to driver her to work so that I could piss around with the X. Off course we left the house and the 4wd was engaged. Got out on the highway and the road conditions where good so 4wd wasn't needed. I pushed the button and it turns off. Hit it again...nothing. I try several random button pushes on the way there and nothing.

      Drop her off and heading home I hit the button...holy shit it work. So I turn it off and try again. Still working:thumbsup: So I made several random button pushes on the way home and it work...on the highway. A soon as I slowed down or came to a stop nothing happened.

      As I sit making my way home through the city I came up with a theory. It must be binding up or something along that line. I think that when the truck get warm and there is slack in the drive line it will shift. So I'm going to test this theory out today by loosening the bolts realigning the motor and give it a shot.

      I'll post the results when I'm done.
       
    19. DeRocha

      DeRocha NEX Vice President Elite Explorer Moderator Emeritus

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      The relays clicking in the back indicate the 4x4 computer has received input from the button press and have tried to engage 4x4 but failed. The failure could be related to the geared position sensor being "lost" in which case the computer would have no idea which position the T-case is in and therefore do nothing.. You could try gently taping the shiftmotor to jar the sensor into making better contact.

      It could also be related to the shift motor having a hard time moving the shift selector.. If this is the case test have a helper push 4x4 while you feel the shift motor to see if it is working. If you cannot feel the motor then test the wire(s) going to the motor for 12v. If the motor is getting 12v for several seconds it means the geared sensor is not lost but the motor is too weak to move the selector all the way to the 4H position). When was the last time you replaced the T-case fluid?
       
    20. Yeti35

      Yeti35 Guest

      I have to give a big thanks to this site for my 96 Limited seems to be working great now. I found this thread through a search and after reading it I was able to complete my issue with my Transfer motor. I had already torn it apart, cleaned and reinstalled it. I then tried it out to see if it worked and it seemed to, so I thought well I saved a bunch of money not taking it to the dealer. I left my wife have it, since it is the car she drives, and it snowed the next day. I told her to use the 4WD Auto just to get some use and when she did the lights started flashing again. I searched for a solution, found this thread and did some reading. I did not even think to look at the stop closely on the back of the gear for mine was in one piece. I also saw the comment about disconnecting the battery to reset the module. I thought this is gonna suck if I have to crawl back under there to remove the gear and see the stop is deformed. I thought first I am going to try the battery reset and damn if that did not straighten everything out!!:D I went out and tested it in 4WD high and Low in a fairly covered parking lot and so far so good. I will keep this site in my favorites for future reference and I am glad I found it. Thanks again for the info and this site rocks!! :thumbsup: :)
       
    21. LXNavajo_94

      LXNavajo_94 Active Member

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      With help of this thread Im back to having 4wd again woohoo this write up is the best. I do have a suggestion however when I was installing the brushes in the motor. I was having trouble holding them in and putting the rotor in at the same time. I took 2 small zip ties and used those to hold the brushes in till I got the rotor in. Then I used my side cutters and cut the ties off and pulled them out. It took a couple of extra minutes but was alot easier than trying to chase a wayward spring around the shop floor.
       
    22. DeRocha

      DeRocha NEX Vice President Elite Explorer Moderator Emeritus

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      Thanks for the suggestion.. it is notable and will help others attempting this fix. When attempting to re-install my armature it was slightly tricky as you needed three hands to do it.. I used a couple of plastic hobby spring clamps as seen in the left picture below. These were strong enough to hold the brushes, but small enough so the armature and housing could be installed.

      [​IMG][​IMG]
       
    23. davidtg

      davidtg New Member

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      Great thread all - much appreciated.

      I'm in the middle of working on my shift motor and its off the t-case and I've removed the 3 torx screws but am a bit stumped on how to get out the large gear to check the bushing. Its inside the housing so someone's mention of a gear puller won't work...seems I need to press it out from the shaft on the other side? Wonder if someone could explain what they did on this step of the job.
       
    24. DeRocha

      DeRocha NEX Vice President Elite Explorer Moderator Emeritus

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      NO PULLER :nono: it will damage the gear..
      The geared sensor just sits in the housing on top of the worm gear.. you should be able to rotate/wiggle it back and forth and pull it off..
       
    25. davidtg

      davidtg New Member

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      Thanks. Used a dull bit in my drill press to just press it out from the shaft side - didn't take much force at all.

      The bushing was smashed as typical - replaced it with a rubber one that fit and reassembled/reatached the shift motor. 4x4 is back working again - hurray and again thanks to all the posters for this helpful thread.
       
    26. CBII

      CBII Active Member

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      The T-case fluid was changed when Installed the tranny...back in Nov.
      I haven't had time to do any testing. I'll do it tomorrow and post back. I believe that you're on the right track about the motor not being strong enough. The outside temp has warmed up a lot in the last few days (-20c to +1c). The motor shifts quite well know when it's warm. Perhaps it's binding or perhaps the grease is freezing?
       

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