sean kane
Member
- Joined
- January 23, 2012
- Messages
- 16
- Reaction score
- 0
- City, State
- Arlington Washington
- Year, Model & Trim Level
- 1996 Ford Explorer
Hello everyone this is my first post.
I have a 96 explorer with a 4x4 issue. The 4H and 4L lights flash 6 times in the dash. Sometimes the 4WD works fine and other times it does not.
I noticed that when ever the auto window roll down works the 4WD works and when ever the auto window function does not work neither does the 4WD.
I am fully aware of how the BW4405 works as I have rebuilt several of them. I believe this to be an electrical problem.
I went to the local junk yard and bought the following parts:
Shift motor
GEM module
Vaccum solenoids on passanger side core support fender area
Both driveshaft or hall sensors
All these components were changed with same result.
Sometimes the 4WD will be working even with the lights in the dash not lit up. It is an intermittant problem whatever it may be.
If I hook direct vaccum to the solenoid that goes to the CAD unit the 4WD works and the light comes on. I believe that what ever the fault is it is failing to send a vaccum signal to the CAD to engage the axle.
Although sometimes I hear the shift motor clunk and engage and sometimes not.
The last one I rebuilt I had to do several fixes such as case half bushing where the shift drum shaft rides in the case half. I had to put the aftermarket pin that rides in the shift drum into the stock fork. I had to shim the output bearing. I had to replace the teflon wear guides that hold the viscious coupler. I had to replace the coupler itself. I also had to replace the the piece in the lower planetary that the coupler engages into cant remember what its called.
Knowing the insides of the transfer case I am positive it is not internal. Some of the junk yard parts I have purchased could be faulty. I have not had the vehicle scanned for codes. I do believe this is an electrical issue.
Does anyone know the location of any relays or fuses I could check?
Are there any wiring diagrams I could find to trace exactly where these relays and fuses are to determine which ones they are and if they are even faulty?
I have found several relays and fuses but have no diagrams to identify which are for what??
Any help would be greatly appreciated, I thank everyone in advance for their help.
Sean
I have a 96 explorer with a 4x4 issue. The 4H and 4L lights flash 6 times in the dash. Sometimes the 4WD works fine and other times it does not.
I noticed that when ever the auto window roll down works the 4WD works and when ever the auto window function does not work neither does the 4WD.
I am fully aware of how the BW4405 works as I have rebuilt several of them. I believe this to be an electrical problem.
I went to the local junk yard and bought the following parts:
Shift motor
GEM module
Vaccum solenoids on passanger side core support fender area
Both driveshaft or hall sensors
All these components were changed with same result.
Sometimes the 4WD will be working even with the lights in the dash not lit up. It is an intermittant problem whatever it may be.
If I hook direct vaccum to the solenoid that goes to the CAD unit the 4WD works and the light comes on. I believe that what ever the fault is it is failing to send a vaccum signal to the CAD to engage the axle.
Although sometimes I hear the shift motor clunk and engage and sometimes not.
The last one I rebuilt I had to do several fixes such as case half bushing where the shift drum shaft rides in the case half. I had to put the aftermarket pin that rides in the shift drum into the stock fork. I had to shim the output bearing. I had to replace the teflon wear guides that hold the viscious coupler. I had to replace the coupler itself. I also had to replace the the piece in the lower planetary that the coupler engages into cant remember what its called.
Knowing the insides of the transfer case I am positive it is not internal. Some of the junk yard parts I have purchased could be faulty. I have not had the vehicle scanned for codes. I do believe this is an electrical issue.
Does anyone know the location of any relays or fuses I could check?
Are there any wiring diagrams I could find to trace exactly where these relays and fuses are to determine which ones they are and if they are even faulty?
I have found several relays and fuses but have no diagrams to identify which are for what??
Any help would be greatly appreciated, I thank everyone in advance for their help.
Sean
