Transfer Case Engagement Issues

dogfriend · December 8, 2005

Here is the applicable part of the schematic. Note that Ckt 779 is the infamous brown wire. Also note that there is a diode shown as part of the TCS relay. This means that current can only flow out of the TCS relay on Ckt 779.

Edit: Actually, looking at the TCS relay, it appears to me that the only time that CKT 779 has power from the TCS relay is during the actual shift from Low to High or from High to Low. Otherwise, there is no connection. Someone please correct me if I am wrong.

sparky1973 · December 8, 2005

well guys i did not have any power to the brown wire. so i did what i said ran a wire from the batt. trew a toggle. and to my surprize it seems to be working fine. seems to have a 3 modes and i can turn it off and have 2 wheel drive. kinda hard to tell if the auto is working right now seems how we have 7" of white stuff on the ground and still coming down and wind is picking up. so we should have lots of fun tomarrow. I cant thank you guys enough. so ill just thank you all once. thank you guys for all your help. and ill let you know how this works as soon as i can. till then keep the wheels down.

gijoecam · December 9, 2005

I believe that the transfer case relay for the positions stays latched while the mode is selected, but I could be wrong. It doesn't show it on the schematics, but I know that guys on here that clip the brown wire between the TOD relay and the S249 splice still have a locked transfer case in 4hi and 4low and turning the BWM switch off doesn't disconnect the xfer case. Based on that, it must be the TCS relay that feeds the transfer case clutch coil.

Sparky,

As for your issue, it sounds like a fried TOD relay or a bad signal coming from the GEM. The TOD relay is on the right side of the stereo opening, behind the corner of the airbag. (Pics are in the gallery in my sig, pull-down menu called 'Explorer Brown Wire Mod')

sparky1973 · December 10, 2005

ok guys here the latest. the 12v switched wire i put in does activate the 4x4 but the servo motor still doesnt turn so all i have is 4 high and 2 wheel drive when i turn the switch off i would still like to get it fixed so that it works right., ware do i start? happy to have 4 wheel though. thanks a bunch

gijoecam · December 10, 2005

In all honesty, that's a tough one to troubleshoot without having the system connected to the NGS test stand at the stealership. One of three things is happening:
A) The GEM is not receiving the proper signals from the switch or other component in the system and it's not calling for a shift or the 4wd. I'd start with the switch and see what's going on there.
B) The TCS relay and TOD relays both took a cr@p simultaneously.
C) One or both of the fuses that feeds all that stuff is blown: Per the diagram above, pull fuse # 7 under the hood (20A mini) then check fuse # 27 (10A mini in the instrument panel) and then look at #10 (30A maxi under the hood).

I highly doubt it's B, but A or C are definite possibilities.

Let us know what you find!

-Joe

dogfriend · December 10, 2005

I would next check for voltage (current) on the brown wire coming out of the TOD relay. The TOD relay and the GEM are behind the dash near the radio. If there is no voltage on the brown wire, then check for a signal on the yellow wire between the TOD and the GEM. The yellow wire sends the signal to turn the TOD on and off.

cantspell · December 11, 2005

hey, i'm having the same problems as Sparky. I've done all the checks he has as well, including the 'brown' wire (that is the wired that does directly into the transfere case right?.

So is the concensus that it's the clutch assembly INSIDE the transfere case?

dogfriend · December 11, 2005

cantspell said:
hey, i'm having the same problems as Sparky. I've done all the checks he has as well, including the 'brown' wire (that is the wired that does directly into the transfere case right?.

So is the concensus that it's the clutch assembly INSIDE the transfere case?

No, if I understand correctly, Sparky is saying that his 4wd works if he supplies 12v to the brown wire; his problem is an electrical issue, not a mechanical problem with the transfer case clutch.

sparky1973 · December 11, 2005

yes you are right if i supply 12v to the brown wire at the t case 4 high works fine. im gonna go to the switch next according to the test taht someone left on here for it my switch must be bad. im just gonna replace it. and if that isnt the problem im gonna go someware else.

IZwack · December 12, 2005

Agreed with all the t-case Gods on here - this is an electronic problem.

However, i do have a 4405 opened up in the other room now so if anyone needs a shot of a certain part, please let me know.

cantspell · December 12, 2005

OK, so it seems that sparky is not getting power to the TOD clutch....defiently an electrical problem...

in my case, i know it's getting power, so mine would not be an electical problem, but probally a mech. problem with the clutch right?

dogfriend · December 12, 2005

Yep. Did you try running it with all wheels off the ground?

cantspell · December 12, 2005

oh yeah, the front didn't budge, well, once it did slighly, but i'm thinking that could just be pressure of the clutch that is static, not enough to make a difference with the wheels on the ground.

IZwack · December 12, 2005

CANTSPELL >> sounds like the transfer case needs to be opened

cantspell · December 12, 2005

and yes IZwack, today it was...and the magnet is GONE, the friction clutches are GONE and i'm replacing the sensor that sets off the 4wd lights....so basically i'm getting are build...1300 can.???

IZwack · December 12, 2005

Wow thats expensive. What do you mean by "magnet is GONE"? you mean its not working any more?

dogfriend · December 12, 2005

IZwack said:
What do you mean by "magnet is GONE"?

MIA?

IZwack · December 12, 2005

ahah so it left.. packed its bags and slipped out of the breather tube.

sparky1973 · December 14, 2005

witch sencor is it that activates the 4 high and 4 lo lights in the dash? i know my lights are good but they dont come on.

IZwack · December 14, 2005

from my experience, the 4HI lights is not connected to any sensor. As long as there is power to the brown wire and the switch is on 4HI, the 4HI light will be on. Even if you've unplugged the connector on the transfer case (or swapped in a manual transfer case) and rotated the switch to 4HI, the 4HI light will still come on.

Transfer Case Engagement Issues

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