How to: - Rebuild 4X4 Shift Motor | Page 30 | Ford Explorer Forums - Serious Explorations

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How to: Rebuild 4X4 Shift Motor

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Could it be that stop bushing causing the problem?
 



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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?
 












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.
 






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?

19402276_10212379828869111_2407902102828702160_o.jpg
 






... 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?

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).
 






thank you thank you .... thank you.
 






Point taken and post revised....I used brake cleaner because it was within reach (and I like the smell :confused: ) -just kidding :D
Hello Brain, Can you tell me what size hose was used or does anyone know where to get that plastic cushen? The cushen on my motor was cracked down one side and is not in two pieces.
 






Need some help here.. Got a 91 ex with the push button 4x4 (not working) and diagnosed the issue with the bushing being the problem. Got the motor assembly off the transfer case along with the cover for the sensor. Now, I cannot figure out how to remove the first “layer” to get to the bushing. I need to get this done ASAP as the truck is going to be driven tomorrow.

924014AB-983C-428B-B6E1-7B5A1EA6E7CB.jpeg
 






The geared sensor on the left can simply be tapped out from the back side.
 






Great thread! and I'll admit that I havn't read all 30 pages of it so my question may have already been addressed.
1-Does it matter if rubber or vinyl hose I used for the repair?
2-Negative ground is to the body ground so I am assuming you put positive power to the RED or YELLOW wire? to make it go one way or the other
3-Is not a question. If the security Torx fasteners can be removed in the first place, Home Depot has a very good selection of SS machine thread (I assume that they are) Phillips and Allen head fasteners which a Philiips Tip Screwdriver is more likely in someone's trail toolbox if you had to perform a roadside or offroad repair.
:burnout:
 






Hello guys,
I've just registered after reading a lot on this forum, but I haven't got a straight answer for my problem:
1992 Explorer Eddie Bauer - automatic
- no lights light up when I start the car
- no lights light up when I press "4x4" or "Low Range"
- no clicking in the back
- did the test on the module: 4 flashes (so it seems to be ok) and I can hear the relay
- under the hood fuse is ok
- in car fuse-box fuse is ok
I just bought the car. Should I take the motor apart or try anything else before?
Thanks!
 






check fuses for the 4x4 system
After that I would plan to rebuild the shift motor
98% of the time in the last 25 years of fixing the ESOF 4x4 systems, the shift motor is 98% of the time the problem
On a 92 explorer there is a plastic spacer inside the rotating assembly inside the motor. The plastic deteriorates and will allow the motor to over travel. = no lights, no response, no nada

By taking it all apart, cleaning the insides and replacing that spacer it usually works like new again. I use a piece of clear plastic tubing to make a new spacer.. Mark the stator body to the lid before taking it apart so you can keep alignment when you put it back together. You will see hash marks if you clean it well enough, so you know what I am talking about
FYI the old motors like yours can be rebuilt many times over their lives as needed and continue to work.
I had my original 1988 shift motor until 350K miles....took it apart and cleaned it about 3 times before I finally converted to manual t case
I have fixed many many many shift motors over the years simply by taking them apart, clean, lube and put back together.
 






Some more (and fresh) info:
I have tested the switch by checking the 1-2 and 1-3 pins on the 5-pin connector that plugs into the module and I was receiving signal when the buttons were pressed (4x4 for 1-2 and Low Range for 1-3).

I plan on rebuilding the shift motor tomorrow, hope it will work out.
 






Hello guys,
I've rebuilt the shift motor and here are the news:
- when I press 4x4the lights turn on, the click in the back is there (both weren't happening before), but the car is not 4x4 and I can't engage Low Range (in Neutral, of course).
I did a test before putting the motor on the case and I saw that the motor was turning the gear only about 10°, not the whole 90°
LE: I forgot to tell: if I press 4x4 again, the lights stay on.
 






if you cant get 4x4 then you wont be able to get 4x4 low.
Try disconnecting the explorers battery for a couple of minutes so the system is ready to "re learn"

You should try shifting from 2wd to 4x4 and then to 4x4 low (stopped and in N) with the shift motor not hooked up to the transfer case
See if it shifts

Also try shifting the t case by hand, with a set of pliers. Does the transfer case shift with pliers?

Now if the motor shifts put it in 4x4
Move the t case to the 4x4 position
Now mount the motor and see if it works


There is an adjustment built into the shift motor, the hash marks I was talking about earlier
Did you mark the alignment of the pieces? When you say "rebuilt" the shift motor what does that mean? clean all contacts? Clean the stator and brushes? Lube the selector and replace the missing plastic stop?
It will not shift if you do not do these things
 






So, I took the motor apart again and I noticed that the position of the cap was not right (I had my marks, but it was wrong from the begining because it din not match the manufacturer makings) so I repositioned the cap accordint to the hard makings on it and the gear case. After that, I made my markings (visible from below) and started putting everything back together. I was really frustrated and this second time I didn't test motor not hooked up (my bad).
It is still not working and the lights are gone (both red dot and the 4x4 on the dash), but the clicks in the back remain. As I can't work the next two days, saturday I'll take it down again and see what else I can do.

Try disconnecting the explorers battery for a couple of minutes so the system is ready to "re learn"
Done that. Nothing changed.

You should try shifting from 2wd to 4x4 and then to 4x4 low (stopped and in N) with the shift motor not hooked up to the transfer case
See if it shifts
Done that after the first try and didn't shift: only ~10-15 degrees.

Also try shifting the t case by hand, with a set of pliers. Does the transfer case shift with pliers?
It shifts.


There is an adjustment built into the shift motor, the hash marks I was talking about earlier
Did you mark the alignment of the pieces?
Yes. After my first try I noticed that the markings did not match so I alligned them again accordint to the manufacturer markings.

When you say "rebuilt" the shift motor what does that mean? clean all contacts? Clean the stator and brushes? Lube the selector and replace the missing plastic stop?
It will not shift if you do not do these things
I have done all of these.
 






I've done some more testing today and it appears to be the electric motor: I gave him 12V and it only rotates very little in both ways. I've cleaned it and nothing changed. On Monday I'll take it to a specialist and by then I'll receive the custom bushing I ordered. If not, I still have a chance to take it from a second Explorer that I received for parts (has no front grill, no left headlight, no gas tank and so on).
 






Minor update:
One of the shift motors is at an electrician to see if he can make it worg (did not work when feeded 12V), but I got another one that tested ok (not on the car, yet): the pin test was ok and the motor turns when connected to a 12V battery.
 

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Update:
I got the shift motor back on the car and is going to 4x4. So half the problem is solved. I don't know what to try for Low Range.
It is not engageing even when it is not connected to the transfer case. I push the button and nothing happened.
I was is NEUTRAL, engine running, brake pressed. I even tried after driving for 20-30meters and also after diconnecting the battery for about 10minutes.
I also swapped the switch and same result. Tomorrow I'll try swapping the Shift Module from the back of the car.
 






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